The LEAN Donut Shop! Lean Documentary | Episode 1

Follow the lean journey of a growing donut shop as it troubleshoots the adoption of lean manufacturing tools and principles.
EPISODE 1 SUMMARY
We introduce the Lean Donut Shop and take you to the donut kitchen where we expose employees to the concepts of VALUE and WASTE for the very first time! You will discover the 8 wastes of lean, define "value," and realize why respect for people is foundational for building a lean organization. Learn with us at the gemba with real examples, spontaneity, and humor!
ABOUT THE LEAN DONUT SHOP
The Lean Donut Shop is a real-life company (aka The Donut Theory, thedonuttheory...) that was birthed in 2020 in the middle fo the COVID-19 pandemic. Starting in a home kitchen, the business took off! It has grown into a temporary shared commercial kitchen and a 1947 Ford Half Ton mobile donut truck, and will soon set up shop in its very own storefront.
LEARN MORE ABOUT LEAN
To learn more about lean manufacturing, visit leansmarts.com for quality resources and training. You can also enroll in our online video training at the Lean Smarts Academy to make lean training simple, fun, and engaging for all!
JOIN THE LEAN SMARTS ACADEMY
Find our best bite-sized lean videos online at Lean Smarts Academy.
leansmarts.com...

[@karthikramaswamy6824]

This should be way more popular than it is. This is one of the BEST production related videos I've EVER SEEN! All 10 of our supervisors watched this video during their production meeting today. I overheard it from my office and now here I (the COO) am lol. Our operations executive also watched this and found this useful. This video deserves a like from all 7 of my youtube accounts

[@BNT05]

This video gets new Lean Practitioners and Learners going. "Motion" and "Overprocessing" as two forms of Waste can be a bit confusing to grasp and distinguish. However here in this episode 1, the case of "Measuring and Weighting", we have seen that "Motion" has to do with the movements of the personnel within the work floor in getting things done albeit not adding any value to the product/service (wrong way and it is Waste), while "Overprocessing", are those unnecessary activities put into product/service that do not add value to the same (again, wrong way and it is Waste!). @Daniel at Lean Smarts & others, please correct me here if I am wrong... I believe the next episode is ready. And I can't wait for it...😊

[@NevilHulspas]

As a founder of a now 2 mln € production business, this information is very helpful. Thank you 🙏

[@alvarezjen]

I enjoyed watching this! I will be looking for the rest of the episodes!

[@TheCricketfan123]

As an Industrial Engineer I am so thankful to you for making such a documentary. Seriously love your content❤

[@Loading__________...]

Waiting (waste) for improvement episode . So you better launch it quickly. 😝

[@LeanSmarts]

Haha love this. Yes, we’re on it!

[@rihabzemzem3201]

This video seems to be the best demonstration of lean, it makes lean terms simple and easy Thank you for your effort Wainting for the next episodes 👏👏

[@Fahad_Alkhaldi]

Such a great efforts and demonstration of Lean. Thanks a lot for your efforts 🌺

[@LeanSmarts]

Absolutely! Thank you so much

[@olivier5086]

Hi, I love your videos, Thanks for this one, when the next episode of this serie or a new video will be posted please ?

[@seangallagher3770]

Love it. Thanks Daniel! And you wife is smart!

[@dhlf3602]

Daniel, you've been a blessing to us... We love your videos

[@LeanSmarts]

Thank you so much!!! So glad you enjoy them :)

[@glorykaaya7034]

wow! definitely agree "can a startup work without lean?" I read from a book the acronym "DOWNTIME" for the 8 wastes

[@joaovitorbressan9329]

Seus vídeos são incríveis. Voce explica de uma forma muito simples e fácil de entender!! Thanks

[@LeanSmarts]

Thank you thank you! I’m so glad you’re enjoying and learning from it!

[@learnkaizen]

Great, simple explanation and real world example of how Lean can make a difference! The only negative: I want a doughnut 😂

[@jeffreyfriasvillafan]

Just a great video, thanks for sharing your knowledge!

[@LeanSmarts]

Of course! Thanks for watching and supporting our lean adventure :)

[@ismaelhall3990]

Cool.

[@mikebrown7609]

This is a great idea. Please continue making these videos.

[@joe_zupko]

Love what you’re doing with these lean videos. Been thinking though, why are so many lean videos nearly 10 years old? Was it trendy back then or something? Still seems pretty relevant. Been using these concepts with my GF on a bath products business for the past few years!

[@LeanSmarts]

I don’t know! Some of my favorites are older ones. A lot of the better (more engaging) videos are put out by 2 second lean companies. If you register for a free community account at Lean Smarts, you can get access to a listing of some of my and the community’s favorite KZbin videos! leansmarts.com/community/

[@brendamagee6411]

When you speak of waste, there is actual procedures to cancel the "waste" of donut making; use a true donut cutter with the center hole attached, 1/2 the "motion." The employee "waiting" for the donut to fry, larger fryers with large screens, will cut down on the "wait time," same on the frying aspect, a larger fryer with screens eliminates handling the product multiple times.

[@samv5475]

are you still posting? How is your opening doing?

[@haneenashour5345]

Ur videos are the best ♥️♥️♥️♥️

[@willbaack7997]

The old donuts are crumb topping, not waste! Strudel etc... not waste.

[@WH33LMAN18]

So at what point does just in time clash with supply chain issues? How are you meant to balance that in the current supply climate? I work in continuous improvement/ 5's and this is something I struggle with.

[@LeanSmarts]

It is true that a JIT system requires a higher degree of stability to work. When stability is lacking, the system will send feedback more immediately (i.e. production might shut down). Increasing the order quantity etc doesn’t solve the problem of supply chain instability. You will still have stock outs. Also, you might actually make the supply chain instability worse by sending purchasing signals to suppliers that are not coupled with real or timely demand. But also, then you have to deal with the problem of excess inventory internally. Lots of companies are currently dealing with this issue post COVID. They’re bursting at the seams with inventory and paradoxically not always able to produce because of a part shortage. When inventories are so high, internal delivery metrics suffer too because part pickers etc are less efficient and struggling to get parts delivered on time to production lines.

[@LeanSmarts]

You can’t solve supply chain instability with 5S/continuous improvement on the production floor. It’s a separate issue. Of course you know this. My guess is you’re asking the question because you’re encountering attitudes of “what’s the point” when supply chain instability has the power to shut down a line entirely etc. I’ve been witnessing this. But in my opinion it’s a cop out. People say this as an easy out, and to remove any personal responsibility to kaizen and improve. It’s certainly harder to drive improvement in this environment, but is there any better alternative? Right now I know an organization with production lines that are only 50% productive with labor due to wastes. Should we do nothing until the supply chain is fully repaired? I say no. The stakes are way too high, and the markets are full of too much risk to sit on our laurels.

[@whatisleansixsigmabydr.sal4884]

Wonderful job. It's so educational. Congratulations. I think I slightly disagree with your definition of the Overprocessing waste. Overprocessing is adding more value to a product than the customer actually requires such as painting areas that will never be seen or be exposed to corrosion.

[@LeanSmarts]

That’s a very valid definition! I’ve heard it taught both ways. Almost seems to me that it has a “a)” definition and a “b)” definition because of it!

[@Sim-Sim20]

there's a donut cutter you can use for faster production and better shapes..And you guys don't even use a proofer!!

[@Olivetreedisciples3887]

Always utilize the unsold food by feeding the homeless and poor people.

[@yoniesharnessshopllc]

You should have heard my wife complain about your process ☺️ she works at beiler doughnuts in reading terminal market :)

[@yoniesharnessshopllc]

kzbin.info/www/bejne/iGe9da17dq2Fr5I

[@yoniesharnessshopllc]

kzbin.info/www/bejne/g2ilq6eNYqanaMk

[@LeanSmarts]

Wow! That is so awesome. And yes we’ve got a never-ending distance to go!!!

[@zefsurvival7962]

Great ideas but lots of smoke and mirrors. The employee's will eventually learn that their are limits to their value in the business. If they truly had value then they would have a equity stake in the business profits... it would then be a cooperative system.

[@LeanSmarts]

Zef, you should come visit us!

[@zefsurvival7962]

@@LeanSmarts I would love to.

[@LeanSmarts]

The Donut Theory’s storefront opens this month in Knoxville. We’re nothing close to a world-class lean organization at this time, but the offer stands. My wife and I actually love the idea of an equity stake for our employees. The business is simply too new right now to explore it. But we’re familiar with it. I worked for a 100% ESOP out of college. Wonderful experience. I observed though that an equity stake is not a guarantee that employees are engaged at the highest level.