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screen printing => General Screen Printing => Topic started by: CBCB on December 18, 2019, 08:37:29 AM
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Hey y’all, just wanted to share a video I put together.
We make improvements around the shop daily, and use videos to explain and communicate them across the team. I figured that some of the better ones were worth sharing, so I tossed a couple into a montage video here.
Couple gems throughout by my favourite is the way we started bookmarking suppliers/brands for purchasing.
Lemme know what ya think. I’ve got a couple more clips in the bank already so montage #2 is already underway.
https://youtu.be/NlATW0VpYGA
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Thanks! Very helpful. It's all of the little things, (walking 10 less feet 15 times a day) that we don't think about that count.
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Good stuff! Thanks for sharing!
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Thanks! Very helpful. It's all of the little things, (walking 10 less feet 15 times a day) that we don't think about that count.
Yep exactly. Start with finding the seconds and the minutes will follow! Thanks for watching Dan.
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Good stuff! Thanks for sharing!
It’s truly my pleasure!
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Good stuff! I heard some things that made my ears perk up. If you need any advice regarding TPS, hit me up. I’m a 25 year veteran in Toyota (my day job).
...and it’s “con bon”, not “can ban”. :-)
Terry
http://www.AllegiantGraphics.com
https://www.Facebook.com/AllegiantGraphics
https://www.Instagram.com/AllegiantGraphics
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I thought is was kanban?
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That is correct spelling. I was referencing the pronunciation of kanban.
I thought is was kanban?
Terry
http://www.AllegiantGraphics.com
https://www.Facebook.com/AllegiantGraphics
https://www.Instagram.com/AllegiantGraphics
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Thanks Terry, would love to chat. And yes I am heavily leaning on Japan and Lean. It really really screams at me like ‘this is for you’.
Would love to chat a bit. Facebook maybe?
Can you recommend a book or two? Besides the Toyota way. Thank you!!!
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Thanks Terry, would love to chat. And yes I am heavily leaning on Japan and Lean. It really really screams at me like ‘this is for you’.
Would love to chat a bit. Facebook maybe?
Can you recommend a book or two? Besides the Toyota way. Thank you!!!
Anytime. Terry Melanie Martin on FB
I really don’t have any suggestions on books off the top of my head. I’ll think about that. But do some googling on Eiji Toyoda’s visit to Ford. It is said that his trip changed the automotive industry forever. Cool story!
But, I do like what you are doing. Our people are our most important resource. Involving them at each stage of development and production is critical to thorough understanding and gaining their commitment to follow the goal. You mentioned a morning meeting - we do a 6 minute meeting before each shift, to stretch and share relevant process or company information before starting work.
Continuous improvement or kaizen is also a very important initiative - and the kaizens don’t have to be big. In fact, lots of small ones are better - when that is happening, your team members are engaged and looking for opportunities to make things better. Score!
Never forget - Respect For People and Continuous Improvement. 2 main pillars of TOYOTA.
Be happy to share more if the forum is open to that.
Senior Quality Engineering Manager
terry.martin at Toyota dot com
...and a garage screen printer! :-)
Terry
http://www.AllegiantGraphics.com
https://www.Facebook.com/AllegiantGraphics
https://www.Instagram.com/AllegiantGraphics
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Terry, I’m sure I speak for the other two. The more education we can share that applies to efficient production the better. Book suggestions, theories, policy, procedures, and good habits, all encouraged.
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Terry, I’m sure I speak for the other two. The more education we can share that applies to efficient production the better. Book suggestions, theories, policy, procedures, and good habits, all encouraged.
100% agree here.
And thanks again Terry. Respect for people is what’s hitting me hard lately. Island mentality like, we need to respect each other and do good work because our world is small and we will see each other again. And respect for resources, time and materials and the funds from our clients (neighbours).
I sometimes feel like we are still a bit ‘slow’ because of it. We don’t put up huge numbers on our single auto. But it feels like it’s getting close to where all the systems are really working together. Flow is coming!!!
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2 Second Lean:
https://youtu.be/zbL4LwmWAy0
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2 Second Lean:
https://youtu.be/zbL4LwmWAy0
This is where i started! His new book ‘Bannish sloppiness’ is really good too. 2sec lean was literally a life changing concept for me. Like wow, it can be easy and even fun to implement lean culture. Definitely helping me get a hold on the basic concepts. We started with 3S and the daily meetings, now we almost have kanban for everything. And now working on videos for processes. The journey continues!!!
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I started listening on YouTube to 2 second Lean, really interesting. Thanks for posting.
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You definitely have me rethinking some of the moves I make each day. Thanks for posting that.
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Terry, I’m sure I speak for the other two. The more education we can share that applies to efficient production the better. Book suggestions, theories, policy, procedures, and good habits, all encouraged.
I sometimes feel like we are still a bit ‘slow’ because of it. We don’t put up huge numbers on our single auto. But it feels like it’s getting close to where all the systems are really working together. Flow is coming!!!
Sometimes you have to slow down to speed up. :-)
...is speed the issue you are struggling with or First Run Rate and achieving productivity expectations? Anybody can achieve the number, but hitting that number within the allocated shift hours is where I see manufacturers (in my day job world) struggle. Reworking product is waste and we should always strive to eliminate the waste. If you’ve got time to “redo” it, why didn’t you have time to do it right? Quality activities should be incorporated at each stage of the process - do not pass on defects. Stop the process, fix the defect, and restart the process. Then measure your downtime (line stoppage) and use as a kpi for your organization. Secs, minutes, etc - whatever is relevant to your cycle time.
Some of this is easier said than done, but downtime and defect repair costs are significant - and sometimes hidden/invisible if not tracked. You just wonder “why didn’t we ship that job on time/earlier?”
Terry
http://www.AllegiantGraphics.com
https://www.Facebook.com/AllegiantGraphics
https://www.Instagram.com/AllegiantGraphics
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I started listening on YouTube to 2 second Lean, really interesting. Thanks for posting.
Literally changed my life!!
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You definitely have me rethinking some of the moves I make each day. Thanks for posting that.
You should rethink every move you make every day!! You’ll continue to find waste. Or you can ‘settle’ for less! That’s how I see it now. Either we work to improve, or we don’t improve.
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CBCB when I saw your first video I thought that this guy has lost it. Is bored and has no work. Since then I’ve listened to 2 second Lean, watched lots of videos and am now listening to the the Toyota story and see that your a smart guy.
Thanks for introducing me to Lean, I’d never heard of it before.
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CBCB when I saw your first video I thought that this guy has lost it. Is bored and has no work. Since then I’ve listened to 2 second Lean, watched lots of videos and am now listening to the the Toyota story and see that your a smart guy.
Thanks for introducing me to Lean, I’d never heard of it before.
Thanks Maxie. Sometimes I think I’ve lost it too haha. It’s a balance, Lean isn’t the perfect system but I think it’s based on a lot of fundamentals that are perfect for our industry.
Like reducing waste, simple inventory for materials like ink, daily meetings to train and improve etc.
I tell my guys all the time that dirty shops make money. When we look at crazy shops I stress that those guys are making good money. But that it’s not easy.
My biggest fear starting this business was being too busy. I never wanted my biggest problem to be handling the volume. I worked in a shop where the main stress was getting crap done, like where the the car is moving too fast to fix it. Sometimes you gotta slow down to go fast...
I don’t know much but I know that I’m getting better at teaching my team to understand waste.
At the end of the day we spend a maximum of 20% of our time on improving the process. Seems like a lot but it’s just a chunk of each day.
I have considered switching it up a bit though. The guys have suggest a four day work week, of 10hr shifts. With our morning 3S and meeting that’d compress their improvements into like 15% of payroll time. Just a thought.
Anyway thanks again. I really appreciate it and i love seeing other shops learn about respect for people and resources!
I have another one of these videos ready to go. Perhaps I’ll just update this thread with it instead of making a new one.
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Hey yall! Back with montage #2. I’ve got another video here with a bunch of improvements from around the shop. Lots of simple stuff so lemme know what you think and if you have any suggestions or questions!
https://youtu.be/aOoazU_cg_Q (https://youtu.be/aOoazU_cg_Q)
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1:24.... You may want to rethink that. Breaker panels must be easily accessible. No furniture or other obstructions should be placed in the working space, making it easy to approach the front of the panel.
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1:24.... You may want to rethink that. Breaker panels must be easily accessible. No furniture or other obstructions should be placed in the working space, making it easy to approach the front of the panel.
Thank you! Yeah that’s kind of an odd one for us because whenever an inspector mentions it they never follow up to clarify what the parameters are for clearance. A lot of that stuff doesn’t protrude further than the box itself! We have a similar issue with the darkroom ceiling and the sprinklers. Apparently it’s an issue but not big enough that they can make what the issue actually is haha.
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1:24.... You may want to rethink that. Breaker panels must be easily accessible. No furniture or other obstructions should be placed in the working space, making it easy to approach the front of the panel.
Thank you! Yeah that’s kind of an odd one for us because whenever an inspector mentions it they never follow up to clarify what the parameters are for clearance. A lot of that stuff doesn’t protrude further than the box itself! We have a similar issue with the darkroom ceiling and the sprinklers. Apparently it’s an issue but not big enough that they can make what the issue actually is haha.
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36" clearance in front of circuit panels and switchgear
sprinklers - i dont know if its specific to the type we have in our building, but we were told 18" clearance below the sprinkler head.
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I like what you’re doing! Eliminate the waste is the most important aspect of the Toyota Production System. ...and it’s a BROAD aspect when you think about it and define waste. ...garbage, time, resources, money, garments, etc, etc.
As an example, are you tracking your scrap and reflecting on some frequency? Is it visual (on the wall) for your team to review with you? PDCA. :-)
...as I mentioned before, you are on the right track. Your team members have all the answers. Your job (as a leader) is to draw it out and ensure the improvements are sustainable.
Terry
http://www.AllegiantGraphics.com
https://www.Facebook.com/AllegiantGraphics
https://www.Instagram.com/AllegiantGraphics
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Thank you so much! Yes I am starting to get a clearer picture of where I’m at on the lean journey now. I feel like we have a good handle on 3s, daily meetings, and now filming the improvements and working on explaining the concepts. And getting a pull kanban inventory system going i think we have 90% of items carded now. The team is learning for sure like the engagement feels strong.
Lately I have been stressing that factories for Toyota and Honda go years without sending a defect to a customer. We made a list of reasons why defects make it to customers whether it be shortages or misprints or garment defects. But the list was pretty short.
Our first sign for scrap is ‘days without pinholes’ hahah. I feel like that’s our biggest reason for press stoppage right now so we’ve been dialling in the darkroom, that’s our ‘rock’ for the next 90 days. Which includes the pre-reg in the darkroom.
It all works well here and the concepts seem to build on each other well too. So I’m pumped to keep going but not sure what’s next yet! Haha
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Are there any book you would recommend.
Looking for the practical side of Lean
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Are there any book you would recommend.
Looking for the practical side of Lean
I would have to say Two Second Lean by Paul A. Akers. Super easy and kinda just focusses on the starter concepts. Keep it simple and fun.
The book rules and you can see him read it or at least narrate it in different talks that are on YouTube. Plus all the tours of his business that he shows different improvements and the general workplace cultured, that’s kind of what got me hooked! Enjoy and holler if you have any other questions.
I just finished reading the Toyota Way and am reading Traction now. Both seem to be good companies to lean thinking.
I also liked and implemented Profit First. Or most of it. It feels like a ‘Lean’ way to see cashflow without reports, just scheduled transactions. Forces you to adjust to problems right away, not when the bookkeeper chimes in.
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This is all good stuff! I applaud you for taking these steps! Again, TM engagement is key. You want their mind in YOUR game for the shift. Involving them, expecting them, and praising them for their process improvements is a good start to keep them engaged.
What did your team say when you asked them ‘what’s next’?
Some questions I ask...
- what frustrates you most about your process?
- I’ve been thinking about xxxx(insert YOUR top concern here), what do you think we can do to make it better?
- we missed xxx (target) yesterday, last month or whenever - what ideas do you have to help us achieve the goal?
At some point, you may be overwhelmed by the elephant that could be the focus. I’ll share later the Toyota approach to problem solving - TBP (Toyota Business Practice), which helps to tackle the elephant.
Terry
So I’m pumped to keep going but not sure what’s next yet! Haha
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Thank you! Yes team engagement is where this all started for me. I was frustrated after my first hire thinking that I can’t improve both my own processes and theirs. Best person to suggest it is the one in the job, IF they can see the wastes.
My guys submit more videos than I do probably but I try to only include ones with deeper explanations for the montage, which I’m encouraging the guys to keep in mind. Teaching is understanding.
Our biggest problem right now is pinholes. If we want to be perfect then that’s something we gotta work on. So just making a list of everything related and that’s our ‘extra’ work beyond 3s. Today my 3s was trying to get our DIY ink mixer a little more dialled in.
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I’ve seen you mention 3s a few times. Which 3 of the 5s’ are you focusing on?
Terry
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I’ve seen you mention 3s a few times. Which 3 of the 5s’ are you focusing on?
Terry
Haha that’s a 2Sec Lean thing for sure. Shine, Sort, Standardize. This is how I understand it and how I’d articulate it to someone new at the shop:
Shining is cleaning, the core of this is inspection. So starting by tidying our workstation.
Sorting is an extension of cleaning. Repetitive sorting makes a good candidate for something that needs to be Standardized. So this is mostly removing anything not related to the value at that process. Or adding anything that is. Mostly the goal of sorting is to reduce your shining and get the workstation ready for the day by filling consumables and making sure everything is set.
Standardizing. Fixing what bugs you. If you keep having to put the tape back, give it a spot. Or bolt it down. Or put tape to wherever the tape keeps going. It’s all about making a tiny tiny adjustment that makes the job easier.
Guys have got 30min first thing in the morning for this. Before our meeting. People vary (only four of us) but I mostly spend the whole time standardizing something, while the rest of the team starts with cleaning.
It really helps to keep a running list of quick improvements to do so that the time isn’t wasted.
We do 15min brainstorming sessions on a corner of the shop and then there’s a week or two of odd jobs to fill time with! This really helps get through the morning fog when all you can think of doing is vacuuming the floor but you really want to submit an improvement video for the meeting.
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Ok. Let me give you something to think about with regard to ‘standardize’.
Think of standardize as documenting the expectation. What is the standard? (or spec)
As an example, at Toyota we have standardized work. In the standardized work, we detail all of the elements for completing a task. To install an alternator, you need this wrench, you mount alternator in this orientation, you tighten fasteners to this torque, you check your work for quality, etc. Those steps are listed in order from start to finish.
Now, incorporating standardized work into a manufacturing environment is a management responsibility. Following it, is the TM responsibility.
How do I know the TM is following the standardized work? I grab the standard (standardized work) and audit the TM to that standard. If I find NC’s, I give immediate feedback and explain why following the standard is important. With no standards, everyone is running wild! Haha
Management can’t complain if standards are not correct, clear, trained to.
Terry
I’ve seen you mention 3s a few times. Which 3 of the 5s’ are you focusing on?
Terry
Haha that’s a 2Sec Lean thing for sure. Shine, Sort, Standardize. This is how I understand it and how I’d articulate it to someone new at the shop:
Shining is cleaning, the core of this is inspection. So starting by tidying our workstation.
Sorting is an extension of cleaning. Repetitive sorting makes a good candidate for something that needs to be Standardized. So this is mostly removing anything not related to the value at that process. Or adding anything that is. Mostly the goal of sorting is to reduce your shining and get the workstation ready for the day by filling consumables and making sure everything is set.
Standardizing. Fixing what bugs you. If you keep having to put the tape back, give it a spot. Or bolt it down. Or put tape to wherever the tape keeps going. It’s all about making a tiny tiny adjustment that makes the job easier.
Guys have got 30min first thing in the morning for this. Before our meeting. People vary (only four of us) but I mostly spend the whole time standardizing something, while the rest of the team starts with cleaning.
It really helps to keep a running list of quick improvements to do so that the time isn’t wasted.
We do 15min brainstorming sessions on a corner of the shop and then there’s a week or two of odd jobs to fill time with! This really helps get through the morning fog when all you can think of doing is vacuuming the floor but you really want to submit an improvement video for the meeting.
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Terry
http://www.AllegiantGraphics.com
https://www.Facebook.com/AllegiantGraphics
https://www.Instagram.com/AllegiantGraphics
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Got another video for the series here, and another montage of improvements.
First video is a quick explanation of how I let everyone on our team implement their ideas and improvements without it turning into absolute chaos.
https://youtu.be/IVeJoM38eFQ
Second one here is a montage of recent improvements, similar to the first two videos in the series.
https://youtu.be/TbuekFXhldM
Lemme know what you think - but I'm thinking this might be my last contribution to the board with the way veterans are brigading. I loved this board because it specifically was not an echo chamber. Fingers crossed that I'm able to share more ideas and challenge old processes.
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Ok. Let me give you something to think about with regard to ‘standardize’.
Think of standardize as documenting the expectation. What is the standard? (or spec)
As an example, at Toyota we have standardized work. In the standardized work, we detail all of the elements for completing a task. To install an alternator, you need this wrench, you mount alternator in this orientation, you tighten fasteners to this torque, you check your work for quality, etc. Those steps are listed in order from start to finish.
Now, incorporating standardized work into a manufacturing environment is a management responsibility. Following it, is the TM responsibility.
How do I know the TM is following the standardized work? I grab the standard (standardized work) and audit the TM to that standard. If I find NC’s, I give immediate feedback and explain why following the standard is important. With no standards, everyone is running wild! Haha
Management can’t complain if standards are not correct, clear, trained to.
Terry
Sorry Terry, I missed this! You are TOO RIGHT about training. Our training sucks! And training in our industry sucks! I think it's because the standards are lower. There are Lexus suppliers that haven't sent a defect to their customer in THREE YEARS STRAIGHT. How many of us can say that? That we gave exactly what they paid for every time? Insane, and they are doing way more volume and way more technical processes like welding, mold injection, die stamping etc with 100s of points of inspection compared to a tee.
Here is the video that changed my mind. From Paul Akers about how their training sucks. Even though they have QR codes for videos of pretty much every process in their facility, like 1000 process.
https://www.youtube.com/watch?v=d8WGcxHpLE4 (https://www.youtube.com/watch?v=d8WGcxHpLE4)
My job changed this year. I no longer am a production manager, I am a continuous trainer. Contious mentorship while we strive for perfection!
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Keep the videos coming. I’m no veteran or large shop in screenprinting. ...I’ve barely got a part time shop lol
But I do have over 30 years in the automotive industry - 20+ in Toyota manufacturing (quality engineering). So I’m happy to help with TPS
...and why did I decide to start a screenprinting part time business at 49 years old??? Lol
Good luck!
Terry
http://www.AllegiantGraphics.com
https://www.Facebook.com/AllegiantGraphics
https://www.Instagram.com/AllegiantGraphics
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Thanks Terry! It doesn’t matter how many presses you have or volume you do. I’ve been learning since day one in the basement from shops of all sizes!
Lotsa places and people think that because their business is larger that they must have a higher degree of wisdom.
When I think of Lean I just think it’s an attitude, a level of respect for resources and people that is totally missing from veterans in this industry.
The amount of times I’ve been told something like “oh well when you do volume it’ll make sense”. Or “oh our team is too big for that”. Gives me a chuckle.
I am obsessed with this stuff. Far from an expert, but I truly believe our industry as a whole would benefit from this thinking.
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Back with another bunch of improvements in the shop. Hope this gets your gears turnin'!
I'm falling a bit behind on these (I have two more montages ready to go!) so I'll have a another bunch of ideas in a couple days.
https://www.youtube.com/watch?v=9r3gaqfihM8 (https://www.youtube.com/watch?v=9r3gaqfihM8)
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I really enjoy these...if anything it makes me stop and actually do things I've been thinking about improving.
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I really enjoy these...if anything it makes me stop and actually do things I've been thinking about improving.
Thank you, super glad to hear.
It truly is just about fixing what bugs you. I’m guilty myself of thinking about things and then settling for the way they are as good enough. But making a conscious effort to improve something at the START of every day, so that you can enjoy your improvement all day and then be stoked to make another tomorrow. Defects go down, costs go down, quality goes up, customers are happy. Boom boom business.
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New video today! Been getting so much feedback and questions about these improvement clips. It's only been a couple days but here is Volume 5. Bunch of new ideas in here that have been helping us around the shop, so I hope it helps someone else, too!
As always, questions and feedback are appreciated, because talking about these ideas is the best way to keep improving on them and exploring new solutions to old problems.
https://www.youtube.com/watch?v=hAg5Fq39gfE (https://www.youtube.com/watch?v=hAg5Fq39gfE)
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Hope everyone is having a great Thursday. I've got another batch of improvement videos from around the shop to share. Trying to get one up every week!
https://www.youtube.com/watch?v=mgXuU96dIrw&list=PLYIDLKn1N1mJkt25gPzUhIZ7zeeFKtoSF&index=1 (https://www.youtube.com/watch?v=mgXuU96dIrw&list=PLYIDLKn1N1mJkt25gPzUhIZ7zeeFKtoSF&index=1)
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Been a while, but I'm back with some more little improvements to share. The busier things are, the more important it is to stop and Fix What Bugs You.
Figured I'd drop an update here instead of starting a new thread.
Hope this helps someone!
https://www.youtube.com/watch?v=gU2zxJNVKFA (https://www.youtube.com/watch?v=gU2zxJNVKFA)
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Back with another one. I spent some time in the darkroom dialling things in a bit more. Hope this gets your gears turning:
https://youtu.be/qVIdlExKiJg
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I’ve just went in on a few of these and It’s been great content. Valuable stuff here.
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Nice and clean, and yes I need my gears started ;D