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Sophie Langley

Think Productive: Zero-Cost Lean Manufacturing for woodworking businesses.



If you want to increase profits, the most effective way is to stop wasting them, and that means getting lean. Most of us will be familiar with the principle behind lean practice and in woodwork manufacturing, this tends to focus on reducing costs, waste and cycle time and improving ergonomics, output and accuracy. Lean manufacturing is about getting as much bang for your buck as you can, and it’s the fastest way to make money without spending any.




Where do you start?

There are plenty of great tools available for analyzing flows of material and processing and these will really help pinpoint where improvements can be made and how to protect yourself from variables. For now, we suggest you put those on hold, because there is one critical component to lean manufacturing, and it's often overlooked: the biggest shift for lean manufacturing is state of mind.


For lean to succeed, everyone needs to be on board.

Without a clear understanding of their role and the overall process, then your adoption of lean manufacturing is likely to be less effective.
Employees that are not clear on process generate higher levels of waste. If they don’t understand why or how things are done, that high level of potential waste continues upwards. Encouraging individual responsibility is key to minimizing weaknesses in every aspect of your lean manufacturing.

Disorganization is where time is really wasted, but organization can lead to significant savings, often without any cost. Even with good intent, disorganization can creep up on any business owner, especially in a busy workshop. Whilst it feels like there are no-more available hours in the day, getting organised now will pay real dividends for the future. Wasting less time frees up more time to focus on more important issues, such as sustainable growth and employee retention.


Being organized can save you big bucks, so start at the top.

Changing the way your business operates can feel challenging, but confronting ingrained habits and outdated processes is essential for success. With the right mindset, tools, and support, woodworking businesses can really benefit from improved efficiency and performance.

Full engagement in lean principles is crucial for productivity and profitability, and everyone, from management to operatives, need to be on board. If you aren’t part of it, you are sending the message that 5S isn’t that important. When it comes time to introducing lean practices, being organized is critical and that starts with you.


Even with CNC machines and automation, inefficiency will eat up those valuable production minutes. From machinery choices to workshop layout, organization plays a pivotal role in maximising productivity. Shifting the mindset of your team and getting rid of valuable time wasted by disorganization will create a ripple effect that will inevitably improve your bottom line.

It doesn’t always require big bucks to improve profitability and scalability of your business, and if you involve the team, it’s easier to make the tweaks that can help improve your profitability.


Lean Manufacturing Starts with 5 Steps

We are big fans of the 5S’s of Lean. A straightforward, five-step process that is easy to understand, fosters a culture of improvement and team engagement. By following the principles of sort, set in order, shine, standardize, sustain – it’s much easier to create a clean, well ordered, and disciplined work environment.
Consistency is key – incorporating 5S into daily routine with participation from everyone in your business. It’s a simple practice that sets the foundation for successful Lean Manufacturing.


The Basics of 5S Lean

The 5S framework was developed by just-in-time expert and international consultant Hiroyuki Hirano, who believed that without the habits and organization that comes with adopting 5S, other lean manufacturing tools and methods are likely to fail. It certainly worked for Toyota, and since then – major leading companies, like HP, Boeing, Harley-Davidson, Nike, Caterpillar, and Ford have implemented the strategy.
The 5S principles—sort, set in order, shine, standardize, and sustain—are universally recognized and applied by manufacturers worldwide.



Sort

Start by decluttering your workspace, whether it's a small bench or a larger production area. By removing unused or rarely used tools, hardware, materials and ancillary items - space is freed up and efficiency is improved.

Don’t forget to include extra inventory, broken equipment, leftover materials and waste. There are certain to be miscellaneous items, so simply create a miscellaneous tagging system for ongoing review. As a daily task, keeping on top of sorting items ensures a streamlined workspace and maximizes productivity.


Set in order.

Arranging tools and materials in the most effective way streamlines processes to improve efficiency and reduce stress. Labelling encourages organization and cuts down on time wasted searching for materials and tools. The trick here is to store items where they're most frequently used, not just where they logically belong.
In a woodworking business, some items are shared amongst the team, so continuous organization helps to create adaptable workspaces that over time will maximum productivity.

Shine

With workspace organisation ticked, ‘Shine’ is the next daily task. This routine should cover all workspaces, equipment, tools, floors, etc. Regular cleaning factors inspection time in for machinery and workspaces, so it’s easier to pick up on potential issues and stay on top of maintenance. By adopting 5S Lean, loose fixtures, oil leaks, wiring issues and faults will be picked up early, avoiding disruption to production and quality.


Standardize

There is no point in getting organised without a system in place to maintain those efforts, with consistency across the board. Standardize integrates sort, set in order and shine into a system easily understood by everyone in your business.
Visual management tools like color coding, typefaces, signage, labels, documents and even post-it notes help define areas, tasks and warnings. With a standard system in place, it’s easier to locate items, follow process and spot when something is in the wrong place. Make standardization part of the daily routine, and 5S Lean becomes second nature.


Sustain

Like the perfect dovetail, ‘sustain’ holds 5S Lean together for the long haul. This step creates routines and habits that keep your joinery shop, factory and woodworking business organized, standardized, and ship shape. The goal is to create a team that ‘do without being told’ and the best way to achieve this, is to keep everyone invested in the same goal.

Remember, 5S Lean is about engagement and creating a culture of responsibility in the workplace, not compliance. Involving the team in regular reviews and encouraging suggestions for improvement helps maintain momentum. Hands-on training and learning as you go are effective ways to keep everyone on board. However, the most powerful way to sustain 5S lean, is leading by example.


How to Implement 5S Lean – 5 Top Tips

At Powerline, we work with businesses of all sizes; from small joinery shops to large scale manufacturers - helping to streamline their business with the right machinery. We know that if you want to get the best return on machinery investment, the key is to think productive, and that’s why we like 5S Lean. With almost zero cost (think stickers, labels and maybe doughnuts for those regular check ins) you can transform the ethos of your business, reduce wasted time, materials and improve every element of just-in-time manufacturing.



About Powerline Machinery Ltd,

With 30 years’ experience, we pride ourselves on providing expert and tailored machinery solutions for manufacturers across a diverse range of sectors.

From commercial, retail, and architectural to residential and interior design and consumer furniture to the construction, aerospace, defence, and marine sectors, we work closely with our clients to explore the individual goals and challenges faced.

Get in touch, find out how the most suitable and efficient machinery solutions can support your labor force in maintaining and creating sustainable growth.





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