Mission

1. Mission • Our Mission is to provide sufficient throughput to allow the student crafts warehouse to ship broom craft products within 48 hours from the time the order is placed . Vision • Our vision is to expand the opportunities to spread the Berea message over a wider customer base to increase the circle of influence.

2. Charter • Mission – Have sufficient inventory to ship broom craft products within 48 hours. • Burning platform – There are missed opportunities to share the Berea message through relationships built upon satisfied craft customers. • Process Description – Currently orders are taken and released to craft production in a make to order methodology which results in orders not shipping complete within 48 hrs. • Problem Statement – The broom craft process needs to respond to customer demand and pull products through craft production. • Sponsor – Derrick Singleton • Process Owner – Tim Glotzbach • Team Lead – Deloris Reid and Chris Robbins • Facilitator – Richard Smith • Team – Tim Glozbach, Deloris Reid, Chris Robbins, Jen Salyer, Charlie Gipson, and Richard Smith

3. SIPOC Suppliers Inputs Process Outputs Customers Lack of Finished Goods inventory Standard work not clearly defined Availability of work students prevent continuous flow Work is pushed through the craft areas BC Student Labor BC Crafts staff Raw Material Vendors Craft labor Quality raw material delivered at the right time, right quantity, at the right place and of the right quality Administrative support and training Satisfied Customers Training of students Opportunity to share the Berea great commission Profit Individual retail customers Craft Vendors Work students Wholesale customers Policy Constraints What processes are you bound by, that you must change to change a process? To whom do you provide product, info, services. What inputs are needed to create the outputs? What do your customers need from you? Who provides those inputs?

4. Hi-Level Process Map Broom is finished Broom is machine or hand stitched Broom corn is machine wound or hand rolled onto handle Broom is braided if required

5. SWOT Analysis Enthusiastic leadership. High percentage of returning labor students. Loyal customer base for Berea craft products. Berea craft products command a premium in the market. Difficult to manage flow around student labor force. Do not have a clear capacity/resource estimate for required production. Internal Strengths Weaknesses Opportunities Threats External Application of TOC buffer management for finished goods. Application of TOC buffer management for raw materials. Use TOC red/yellow/green signals to identify the most important work for broom craft to execute. 5S the craft area Educate the staff on TOC fundamentals. High season prevents completion of buffers before February 2014. Wholesale customers place too many customer specific requirements. Software vendor is not capable of making changes to the software to accommodate a TOC buffer report.

6. Gap Analysis Opportunities and Priorities • Lack of inventory to ship from stock • Establish finished goods buffers based on RRT. • Develop buffer report with software vendor. • Develop a proper signaling method for the craft area that will identify the most important work. • Apply 5S and VSM to craft process.

7. Queue WIP Completed Complete ideal future state VSM Establish RRT for each broom. Establish buffer for each broom based on RRT Discussion with software vendor for time and estimate for creating a buffer report. Complete TOC training class for all Broom craft personnel 5S the craft floor

8. February 2014 • Buffer Report

9. February 2014 • Production Report

10. Report Out Notes • As of February 2014 back orders have been eliminated. • Pull system replaced push system. • Inventory is available to ship broom craft products within 48 hours. • Production schedule allows the students to be a self-directed work force. • Freed up time to complete a LEAN 5S project. • Students have completed work credit for participating and completing two lean projects. • Throughput has increased 20% with capacity to absorb demand anomalies. • Potential to pursue additional wholesale customers.

11. Project Team