Transforming Production Efficiency:
A Case Study with Saand's Plant Manager Fawad Rashid

Client

Fawad Rashid uses Toyota Kata to improve their “Rollercoaster” process, a key process that was underperforming.

Saand Inc. is a premier architectural glass fabricator of commercial and OEM glass products providing high quality, value-added glass solutions throughout North America. Saand manufactures a complete range of glass products and services including commercial insulating glass units (IGU’s), ceramic and silicone spandrel, back painted glass, stock and custom laminated, heat treating and heat soaking, sandblasting, as well as, stock and cut size mirror.

"I thought I knew everything... I thought I was the expert. [Kata] allowed me to learn daily about the process and the people."

In this clip, Fawad reflects on what surprised him along his kata journey.

Introduction

  • Title: "Transforming Production Efficiency: A Case Study with Sand's Plant Manager"

  • Subtitle: "Discover how Cost tailored and its coaching approach led to remarkable improvements in Sand's production process."

  • Brief Overview: "Join us as we delve into the journey of Fad Rashid, Plant Manager at Sand, who, with the guidance of Cost tailored's coaching, achieved significant enhancements in his plant’s operations."

Customer Spotlight

  • Title: "Meet Fad Rashid: Driving Change in the Glass Industry"

  • Content: "Fad, with over 20 years in the glass business, is known for his deep expertise in production management. His passion for improving processes and dedication to the industry have been instrumental in Sand's success."

Challenge Faced

  • Title: "Identifying the Core Challenges"

  • Content: "The roller coater line at Sand's plant was underperforming, impacting both business potential and employee morale. The need for a solution was imminent to enhance efficiency and meet increasing market demand."

Solution and Implementation

  • Title: "Embarking on a Learning Journey with Cost tailored"

  • Content: "Through a series of Kaizen experiments and collaborative problem-solving, Fad and the Cost tailored team identified key areas for improvement. This involved scheduling adjustments, optimizing batch processing, and enhancing internal communication."

Results and Impact

  • Title: "Achieving Remarkable Results"

  • Content: "The concerted efforts led to a significant increase in production efficiency. The first hour of production saw an increase from zero to 311 square feet, with an overall daily production jump by $10,000. This not only improved the bottom line but also boosted team morale."

Reflections and Learnings

  • Title: "Insights from Fad Rashid"

  • Content: "Fad reflects on the journey, noting the importance of patience, discipline, and involving business partners in process improvements. His growth as a leader and the team's enhanced collaboration stand out as key takeaways."

Conclusion and Call to Action

  • Title: "Join the Journey of Continuous Improvement"

  • Content: "Inspired by Fad's story? Learn more about how Cost tailored can transform your business processes. Visit truthbitpole.com for more insights into our approach and success stories."