Lean – 5S

One of the Lean Tools that we have used to one degree or another over the last several years is 5S. This is often considered housekeeping and stands for Sort, Straighten, Shine, Standardize, Sustain. However, I am coming to realize that while housekeeping and an organized workplace are the result of 5S, the purpose of 5S is to make problems visible.

At its most basic level, 5S requires that we ask the question “do we have all that we need in the workplace?”, and “do we need all that we have in the workplace?”, then problem solve when the answer is no. Self discipline and continual improvement are central to achieving success – 5S becomes a way of life in the workplace.

Once the workplace is cleaner and more organized, the elimination of waste and the development of standards can more easily be accomplished.  It is a lot of work, but the results will be well worth it!

Systems and Processes

I was watching a Gemba Academy webinar earlier today which mentioned that "Confusion prevents Improvement" and that "Systems and Processes create autonomy and lead to success". As I considered this, I have to agree that a lot of rework is due to confusion - uncertainty about what is required, how it is to be accomplished, etc. Rework (or defects) is considered one of the seven wastes of manufacturing (muda) as defined by Taiichi Ohno of Toyota.

The way to reduce defects or rework is to reduce rejects which requires that we remove the causes of the defect in the process itself. Rework can be due to confusion when building the product, or by lack of understanding of customer and supplier requirements in the design stage. The better we understand what our customer wants, the fewer design changes we will have. As well, if we let our suppliers know exactly what our requirements are, we can get the right parts at the right time.

All of these defects can be reduced by improving our systems and processes. These improvements can reduce the interruptions to production caused by rework as well as the expense. It can also reduce scrap.

As an Engineering Manager I want to improve our design process to make sure that we ask our customers the right questions when we prepare our specifications so that they get exactly what they expect. I want to ask our internal customers the right questions so that there is no confusion when they build the parts for the trucks. I want to work with our suppliers so we get the best component for our trucks. There's a lot of work to do...

Recent Deliveries - St. John's, NL

On August 26, 2013, the St. John's Regional Fire Department in St. John's, NL took delivery of their latest Metalfab Fire Truck.  This Single Axle Tanker is the Department's eighth Metalfab unit.

 

The chassis utilized in this build was an International 4400 SBA Two Door Chassis.  The chassis was equipped with an International Maxx Force 9 330 HP Diesel Engine and an Allison EVS 3000 Automatic Transmission. 

This tanker didn't have a pump installed.  It was equipped with two CET Portable Pumps.  It also had a 10" Newton Dump with a rotating and telescopic and a 4" Direct Fill installed at the rear of the unit. 

The Emergency Warning Light package on this tanker was a Federal LED System.  It consisted of an Aerodynic LED Light Bar, Sentry Rear Beacons, and Federal Quadra Flare LED Intersection Lights.

The single axle tanker body was of an Extruded Aluminum Construction.  The body featured low side compartments on both sides of the unit.  The doors utilized for this tanker were flush mount aluminum doors.  At the rear of the unit, there were rear access storage compartments for suction hose, a portable tank, and sliding trays for hose storage. 



Metalfab would like to thank the St. John's Regional Fire Department for the purchase of their latest Metalfab unit.

Throwback Thursday - Dartmouth, NS - 1992 Top Mount Pumper

A 1992 Metalfab Top Mount Pumper delivered to the Dartmouth Fire Department is today's featured unit for Throwback Thursday.   This unit was one of two pumpers delivered to the Dartmouth Fire Department in 1992.

This top mounted pumper was mounted on a Ford CF8000 Single Axle Chassis.  The chassis featured a Ford 7.8L Ford 240 HP Diesel engine and an Allison MT643 Transmission.  Metalfab fabricated and installed a four man enclosed crew area mounted behind the chassis cab.

The pump for this unit was a 1050 IGPM Hale QSG Midship Pump.  The pump panel was in a top mount configuration.  The Foam System was a Foam Pro 2000.  The poly tank had a capacity of 500 Imperial Gallons of water.  It also had a foam cell of 10 Imperial Gallons and one foam cell of 30 Imperial Gallons.

The Aluminum Body featured high side compartments on the left side of the unit and low side compartments on the right side. 

Recent Deliveries - East Zorra - Tavistock, ON (Tavistock Station)

The Tavistock Station of the East Zorra - Tavistock Township Fire Department took Delivery of this Metalfab Tandem Pumper/Tanker on July 24, 2013.  This unit was the third unit purchased by the township but it was the first Metalfab unit at the Tavistock Station.

 

This tandem Pumper/Tanker was installed on a Freightliner M2 106 Four Door Chassis.  The chassis was equipped with a Cummins ISL 350 HP Diesel Engine and a Allison EVS 3000 Automatic Transmission.  The chassis was complete with Aluminum wheels and dual fender mounted air horns with dual lanyard controls overhead in the interior of the cab.

The pump on this unit was a Hale PSD 840 IGPM PTO Driven pump.  Where this was a PTO Driven pump, it had Pump and Roll Capability.  All piping was stainless steel and the pump panel was in a side mount configuration.  The Poly Water Tank had a capacity of 2,500 Imperial Gallons.  The truck was also equipped with a 10" Newton dump with Rotating and Telescopic chute and Two 4" Direct Tank Fills at the rear of the unit.



The extruded aluminum body featured a combination of high side and low side compartments on the
left side of the unit.  The right side of the unit had a combination of intermediate and low side compartments.  Rear Access to the main hose bed was achieved by a Zico Quic Ladder.  On the left side fender top a portable tank was stored in a manual drop down rack.  The right side fender top had a manual drop down ladder rack. 


Metalfab would like to thank the East Zorra - Tavistock Township Fire Department and the Tavistock Station for choosing Metalfab to manufacture this new Pumper/Tanker.

Throwback Thursday - Oromocto, NB - 1990 Metalfab Custom Pumper/Tanker

Today's featured truck for Throwback Thursday is a 1990 Metalfab Custom Pumper/Tanker manufactured for the Oromocto Fire Department. 

 

The chassis for this build was a 1990 Spartan Gladiator MFD Custom Chassis.  The engine was a Detroit Diesel 8V-92TA 450 HP Diesel Engine.  The Transmission was an Allison HT-741 Automatic Transmission. 

The Aluminum Body featured High Side Compartments on the Left Side of the unit and Intermediate height compartments on the right side of the unit.  A manual drop down ladder rack was installed on the right side fender top.

This truck was equipped with a Hale QSMG Midship Pump.  The pump had a capacity of 1500 IGPM.  The poly tank for this unit had a capacity of 1500 Imperial Gallons of water and 100 Imperial Gallons of Foam.  Flowmeters were installed on all 1-3/4" discharges and the monitor discharge.


In recent years, this unit has had several modifications and is currently still in service with the Oromocto Fire Department.

Recent Deliveries - River John, NS

The River John, NS welcomed their newest Metalfab Unit to its Fleet of Fire Apparatus on July 10, 2013.  This Metalfab Tandem Pumper/Tanker is the Fourth Metalfab unit that the Department has purchased.

This tandem axle tanker was installed on a Freightliner M2 106 Tandem axle two door chassis.  The chassis was equipped with a 350 HP Cummins ISC Diesel engine and a Allison EVS 3000 Automatic Transmission.


This Pumper/Tanker was equipped with a Hale QFLO 1050 IGPM.  The pump panel was a side
mount type.  Each 6" Steamer port was equipped with a Hale Manual MIV (Master Intake Valve).  The water tank had a capacity of 2,500 Imperial Gallons.  At the rear of the unit, a 10" Newton Dump with rotating and telescopic chute and a 4" direct fill were installed.  There was also a 1" valve installed at the rear for filling of Back Pack Tanks for grass fires.


The extruded aluminum body featured Low Side compartments on the left side of the unit and intermediate height compartments on the right side.  The truck was equipped with a Whelen LED Warning Light package.  The doors on the body were a combination of Amdor Roll Up Doors and flush mount doors.  The truck had rear access storage compartments for a 3,000  Gallon Portable tank on the left side of the unit and had rear access storage for a 24'-00" 2 section ladder, a 14'-00" roof ladder, a 10'-00" attic ladder and 2 pike poles on the right side of the unit.  The truck also had storage compartments for wheel chocks in the left side rear wheel well area.

Metalfab would like to thank the River John Fire Department for this recent purchase.