BECOMING THE GO-TO FOR 5S I still think about the aha moment I had 13 years ago when I learned about 5S. Like many of you, I was always thinking about efficiency but lacked a sustainable solution to meet our needs. We would address one thing, only to find that something else was holding us up. Learning about 5S was a game changer. I was a warehouse manager for a medical device manufacturer, and one day, I got an email from the higher-ups. Our company was looking for five people to volunteer for a lean manufacturing team. I had no idea what “lean” was, but hey, I thought, if they needed people for this, I’d be there. For eight weeks, the five of us met for training in different aspects of “lean.” A few weeks in, we got to the 5S principles. I’d always prided myself on having a really organized warehouse, but this — this was another level. The process- improvement principles really struck a chord with me. 5S addressed so many of the areas where productivity was taking a hit and the processes introduced solutions to areas where a lot of waste was happening. This can really improve our operations, I thought. Ready to learn how I could implement 5S at my warehouse, I raised my hand in the class. “Hey, HOWWE FOUND A SOLUTION
orders surrounded by kids’ toys until we moved to a bigger house with a larger room dedicated to orders. They took over my pool table, which didn’t get used for years. Don’t worry — I had plenty to keep me busy. Eventually, we moved into our own office space, and that’s where the 5S Store operates today. We no longer pack orders alongside PlayStations, but we have a pretty good time helping our customers implement customized 5S solutions. We enjoy taking production personnel from the aha moment of learning about 5S to the even more exciting sigh- of-relief moment when they realize there’s a support team out there to help them use it. Barbara and I put our all into making this happen with the help of our stellar team, and Lilly, our chihuahua, makes sure we all stay on task — and don’t leave any of our lunches behind.
this is really cool,” I told our trainer. “Where can I find the materials to do this here?” Unfortunately, she didn’t know of any resources that existed. Back in class, I pulled out my laptop and searched 5S — nothing. Granted, this was 13 years ago, and the internet wasn’t what it is today. Facebook didn’t even exist. But it was clear that those of us who would benefit the most from 5S wouldn’t have the time to implement it, and there didn’t seem to be any resources to help. Why was this? On a whim, I called my wife, Barbara. “Hey, I have an idea for something,” I told her. Barbara wasted no time taking my idea to the drawing board, booting up the PC on our kitchen counter, and learning how to build a website, the 5S Store was born. From there, we’ve never stopped creating 5S support services. We moved the computer into the kid’s playroom, and my mom joined us to help with invoices. Our inventory was stored in the playroom and the basement. We packed
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WHAT MAKES AN 82-YEAR-OLD BUSINESS BOOK RELEVANT? DALE CARNEGIE’S CLASSIC OFFERS TIMELESS ADVICE
BEHONEST Be transparent with partners and clients,and as Carnegie suggests,be quick to admit when you’re wrong.When it comes to conflict,being right won’t win you anything— it’s better to avoid that lose- lose scenario and instead listen to your associate’s point of view.Respect their opinions.Even better, begin with something you know they’ll say an enthusiastic “yes” to. Set your relationships up for success by implementing Carnegie’s timeless,genuine advice, and see the results for yourself.
It’s a tall claim to say that a book will change your life, but this one has had a profound impact on many people. Despite having been originally published 82 years ago, Dale Carnegie’s effervescent classic “How to Win Friends and Influence People” is still recommended by everyone who comes across it, and it’s one of the best-selling books of all time. In 2011, the book was No. 19 on Time’s most influential books list. How has it remained relevant in a massively different, technologically advanced world? Fundamentally, Carnegie’s book focuses on people, who may evolve, but whose basic needs don’t change much.
BENICE Carnegie’s ideas are revolutionary in their simplicity. This is what makes almost anyone who reads the book able to implement them immediately and see results.As Robert Kelsey,author of several business and self-help books himself,points out,Carnegie’s first principle was simply “Be nice.” “That will always be an important thing to remember in whatever business you’re in,” Kelsey says.“His advice will always be relevant.” In the chapter entitled “SixWays toMake People Like You,” Carnegie’s second suggestion is similarly straightforward: “Smile.” We’ve all read science on the
We all need to feel valued, appreciated, and respected. By fulfilling these needs for your business associates, you will indeed win friends and influence them.When it comes to business, showing a genuine interest in the other person goes a long way toward building a lasting relationship, something we all know is key to converting leads into sales.With a message based on relationships, Carnegie’s book hasn’t grown stale with time. Here are three of his suggestions that you can implement today. BE AUTHENTIC Carnegie’s methods for winning people over are, at their core, about authenticity. “Show a genuine interest in others,” he instructs. “Give honest and sincere appreciation” and “Be a good listener.” Adopt this advice by paying extra attention when a client introduces themselves. A person’s name is important, because, according to Carnegie, it may be “the sweetest and most important sound in any language” to that individual.
psychological effects of smiling,but it’s still too easy to forget this simple gesture.
7 x 3.5
7 x 3.5
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As many of you know,when you’re doing the sorting phase of 5S,red tags make the process a lot more manageable.They’re a visual management tool: They let you and your team tag items that don’t belong in an area.With your red tags in hand, organizing your warehouse or plant suddenly becomes doable.
keeping you from optimal efficiency. Teams find million-dollar pieces of equipment, tools they thought were missing, and hardware that they would’ve bought more of. This is what makes 5S such an efficient waste management tool. Not only are you rediscovering items that would have cost you money to replace, but you’re working toward putting everything in its place, which means it won’t go into hiding again. As you designate an area for sorting, remember that tackling an entire warehouse or plant all at once isn’t the best use of 5S. It’s much more effective if you choose an area around 1,000 square feet to start with so that all of the necessary work can be completed. Ideally, choose an area where a set of work processes begin and end. 5S is meant to target the workflow
Before you can tag,sorting begins with
picking an area to focus on.You’ll go through everything in that area—empty every drawer, cabinet,and corner —andmark any items that don’t belong there with a red tag.The red tag items get moved to a predetermined red-tag area.Once everything is marked,you can begin to evaluate your red-tag items.Are they part of that area,but just not in the right place? Do they belong somewhere else? Is it equipment from an outdated process? Do they belong in the garbage? Sorting can transform a space and help you understand many of the problems that are
through this set of processes, so working on one area at a time is the best way to start. A true 5S program never ends, as its foundation of continuous improvement necessitates. Once you get started, though, you’ll be equipped with the 5S habits and solutions any time a new challenge comes up.With The 5S Store as your resource, you’ll have all the supplies you need to get there.
To stock up on your red tags, visit the5sstore.com.
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INSIDE THE CANINE MIND LILLY’SWAREHOUSE Hiya! I’mLilly, office mascot and Protector of the Viscos. Yep, it is my official title! David thinks this is his office, but anyone who knows what’s up knows that I run the place. I may be small, but don’t let that fool you. I keep everyone in line. Around lunchtime, I make sure no one drops any food on the ground. If they do, I’m here to save the day! It’s the best job right after Thanksgiving. Turkey is my favorite.Well, other than playing withmy favorite toy, Sharkie. Don’t worry — I also scare away the man in the big brown truck who keeps trying to sneak in here with boxes. Why would anyone want a toy that’s all wrapped up? How silly. Oh— I think David’s ready to play fetch. I’ve gotta go! Catch you next time!
WHERE DID IT START? THE HISTORY OF LEAN
If you’ve ever wondered where the spark for lean first arose, look no further than the loom. The humble piece of equipment is responsible for inspiring an entire industry to shift it’s thinking, and it introduced the foundations for the process we now know as lean manufacturing. It was the early 1900s,and Sakichi Toyoda scratched his head at the same frustrations that many production managers face today: equipment breakdowns,halted productivity,and projects not being completed on time. Toyoda wasn’t making cars quite yet —Sakichi’s original business was weaving.His company used looms to weave textiles,and the equipment kept breaking down. Instead of throwing his hands up in the air and fixing the broken parts for the hundredth time,Sakachi took a closer look at the entire process and why it wasn’t working efficiently.Seeing that the manual machines required a lot of upkeep for not a lot of output,he built an automated loom.After observing how that machine cut down on waste and breakdowns, Sakichi made multiple machines like it,and he put a system in place that would allowworkers to fix issues on the fly. Instead of looking at one individual machine,Sakichi looked at the process as a whole to see what could be improved.And he didn’t stop at the new looms — inspired by the Kaizen tenet of daily improvements,Sakichi kept inventing new components that improved the entire weaving process and allowed for increased productivity throughout his company. Sakichi’s son,Kiichiro,continued his father’s innovations,eventually applying the same concepts that had been successful for looms to making cars,and Toyota was born.Since the beginning,Toyoda’s processes have been built on the philosophy that “the ideal conditions for making things are created when machines,facilities,and people work together to add value without generating any waste.” Thanks to Toyota’s innovations,we now apply these ideas to our ownmanufacturing processes to eliminate waste and help things run smoothly.
HOLIDAY ROAST PRIME RIB
• 1 bone-in prime rib (6–7 pounds) • 8 cloves garlic, thinly sliced • 2 cups red wine INGREDIENTS
• 4 cups beef stock • 1 tablespoon fresh thyme, chopped • Salt and freshly ground pepper, to taste
INSTRUCTIONS 1. 30 minutes before cooking, remove roast from fridge and let sit until it reaches room temperature. 2. Heat oven to 350 F. 3. Make small slits in prime rib and stuff with slices of garlic. Liberally season with salt and pepper. 4. Place a rack inside a roasting pan and roast prime rib for 2 hours, until medium-rare. 5. To make au jus, place roasting pan with drippings from roast over 2 burners on high. Add wine and scrape pan as liquid reduces. Add beef stock and cook until reduced by half. Finally, sprinkle in thyme. 6. Slice roast and serve topped with au jus.
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INSIDE THIS ISSUE 1 | David Visco Shares his Aha Moment 2 | This Book May Change Your Life 5S Pro Tips 3 | The History of Lean Meet Lilly Holiday Roast Prime Rib 4 | Everything You’ll Need for an Ugly Sweater Christmas
UGLY SWEATER PARTIES
and family members, make sure there are plenty of
refreshments and games, and you’re guaranteed to have a top-tier party.
A few ugly-sweater- themed games that should be on the
A FUN TREND YOU CAN EASILY FOLLOW! It’s speculated that the first ugly sweater party took place in Vancouver, Canada, back in 2001. Since then, the trend has become one of the most popular holiday party themes. Come Thanksgiving, you’ll start to see racks in all types of clothing stores lined with hideous sweaters. If you’re ready to jump on the ugly-sweater-party bandwagon this Christmas season, here a few things to keep in mind. YOUR VERY OWN UGLY SWEATER Ugly sweaters come in all shapes, sizes, and prices. You can head to it new life. Arm yourself with a hot glue gun, thread, and needle, and patch Santa, Rudolph, or Frosty on it. And let it be known that an ugly sweater isn’t complete without sparkles, beads, and sequins galore.
agenda include an ugly gift exchange, which is similar to the white elephant exchange, except with the gaudiest gifts you
can find; an ugly photo booth, complete with terrible, tacky props; and, of course, an ugly sweater contest. This is the only time of year when slipping into a lurid red sweater with a stuffed Santa sewn on the front is considered trendy.
So adorn yourself in the frumpiest, tackiest sweater you can find, and have some fun this December!
WHAT EXACTLY IS AN UGLY SWEATER PARTY? Its rather simple — slip on your favorite Christmas sweater, gather all your friends
Target or a local thrift store to pick one up. However, if you have a sweater that’s
been cozied up for years in the back of your closet or a drawer, now’s your chance to give
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