Professional Documents
Culture Documents
PERFORMANCE
EXCELLENCE
1
2000, QualityToolBox.com, LLC, all rights reserved
Performance Excellence Series
Training Module Elements
Participant manual
2
2000, QualityToolBox.com, LLC, all rights reserved
Table of Contents
Executive Overview
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2000, QualityToolBox.com, LLC, all rights reserved
Model: Performance Excellence
Deliverable Integration of Lean Robust Processes
Through Elimination of the Nine Wastes of Processes: Over production, Delays, Transportation, Process, Inventories, Motions,
Defective Products, Untapped Resources, Mis-used Resources
Feedback
Parameters
Core Business Processes
Inputs Output Service > 99%
Demand Management
Forecasting
1. Customer Supply Management Order Services Delivery:
*Wants • Procurement • order attainment
• Minimal shipment/order
• order entry
*Needs • Inventory/Material • On - time What is needed,
Management in Quantity that is
2. Suppliers Costs: needed at the
Raw Material • Supplier Management Operations Management • low cost associated time it is needed
Sub-Assemblies with customer value focus at a competitive
Products Quality cost
Information Technology
MRO Operational Management • Low to zero defects +
3. Customer Returns Marketing/Sales Finance Engineering Management • Service beyond shipment Flexibility,
Signature Service Quality Management • Feedback Responsiveness
Treasury
Human Resources towards
Non-Signature Service Accounting
Manufacturing Order Fulfillment customer’s wants
Production and needs
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2000, QualityToolBox.com, LLC, all rights reserved
Why Kaizen CPI
Process
Improvement
• Data Driven Methodology to Magnify Impact of
Project
Implemented Process Improvement
Savings
Time
CPI Project
Savings CPI Projects Emphasize
Control and Long Term
Maintenance
Savings
• Use Small Teams to Optimize Process Performance
CPI
by Implementing Incremental Change
• Apply Intellectual Capital of Team Members Intimate
with Process
Kaizen Projects
Emphasize Incremental
Improvements Time
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2000, QualityToolBox.com, LLC, all rights reserved
Expanding the Strategy
Performance Excellence Obtained
by Continuous Improvement
Improvement Tools
CPI Kaizen
• Disciplined Methodology • Philosophical Approach
• Technical Approach • Common Sense Approach
(Quantitative) (Qualitative)
• Data Driven - Statistical • Data Driven - Observation
• Operational Focus • Customer Focus (Takt time)
• Reduce Variation • Waste Elimination
• Focus on Large Impact • Incremental Change
• Larger/Longer Projects • Smaller/Shorter Projects
Complimentary Tools Driving Continuous Improvement
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2000, QualityToolBox.com, LLC, all rights reserved
Comparative Analysis
6 Improvement Methodologies Kaizen/Lean
• Similar in Structure
Measure • Improvements measured against established Evaluate
- Data Collection process - Baseline Process Performance
- Determine Process Potential / Goals • Team oriented - Establish Target
Evaluate Decide
• Different methods used to determine
- Root Cause / Vital Few -Compare solutions
improvement opportunities
- Statistical Analysis - Choose
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2000, QualityToolBox.com, LLC, all rights reserved
Tool Kit Comparison
Major CPI
Tools (6 ) Kaizen Lean Description
8
2000, QualityToolBox.com, LLC, all rights reserved
Performance Excellence:
Expanding the Strategy through Kaizen
Introduction
Wastes elimination
Kaizen Methodology
Integrated Improvement Strategy
Kaizen Project Examples
9
2000, QualityToolBox.com, LLC, all rights reserved
Continuous Improvement
Is the continuous
elimination of waste
10
2000, QualityToolBox.com, LLC, all rights reserved
What Does Kaizen Mean?
KAI + ZEN
To modify, to change Think, make good, make better
= KAIZEN
Make it easier by studying it, and making the improvement through
elimination of waste.
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2000, QualityToolBox.com, LLC, all rights reserved
What is Waste?
Everything we make that
costs something without
adding value to the product
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2000, QualityToolBox.com, LLC, all rights reserved
The Nine types of waste
9 Overproduction
Wastes Delays (waiting time)
Transportation
Process
Inventories
Motions
Defective products
Untapped resources
Misused resources
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2000, QualityToolBox.com, LLC, all rights reserved
Elimination of Wastes and Continuous
Improvement
14
2000, QualityToolBox.com, LLC, all rights reserved
Performance Excellence:
Expanding the Strategy through Kaizen
Introduction
Wastes elimination
Kaizen Methodology
Integrated Improvement Strategy
Kaizen Project Examples
15
2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Methodology
Kaizen improvement
The mandate
One-piece flow
SMED
Visual controls
Kanban
Workplace organization
Standard work
Quality every time
Total productive maintenance
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Improvement is a Team
Multi-disciplinary
Specific mandate
Short delays
Responsible teams
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Improvement
is composed of 4 steps
To Evaluate E
To Decide D
To Act A
To Measure M
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Improvement
is continuous improvement
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Improvement
is NOW !!!
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2000, QualityToolBox.com, LLC, all rights reserved
To Evaluate
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2000, QualityToolBox.com, LLC, all rights reserved
To Evaluate
Tools for analysis
E •The 5 whys : search for root cause
D •Matrix
•Pareto diagram
A
•Fishbone diagram
M
•Distribution histogram
•Check sheet
•etc.
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2000, QualityToolBox.com, LLC, all rights reserved
To Decide
E
D The value of a decision is no greater than the
quality of the analysis.
A
M
Compare all solutions;
cost, feasibility, efficiency, etc.
Choose
Establish measurable objectives
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2000, QualityToolBox.com, LLC, all rights reserved
To Act
E
D
A Communicate
M operators,
other employees from the area
other people servicing the area
Implement decisions
Control their execution
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2000, QualityToolBox.com, LLC, all rights reserved
To Measure
E
D
A
M Compare the results in relation
to the objectives.
Resume EDAM
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2000, QualityToolBox.com, LLC, all rights reserved
Become familiar with the Mandate
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2000, QualityToolBox.com, LLC, all rights reserved
Implement one-piece flow
Analyze
•Identify the products
•Identify the customers
•Understand and describe the Processes
–part/process matrix
–Flow diagram
–analysis of the Process Flow
–Spaghetti diagrams
–TAKT time
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2000, QualityToolBox.com, LLC, all rights reserved
Performance Excellence:
Expanding the Strategy through Kaizen
Introduction
Wastes elimination
Kaizen Methodology
Integrated Improvement Strategy
Kaizen Project Examples
28
2000, QualityToolBox.com, LLC, all rights reserved
Complimentary Continuous Improvement Approaches
Kaizen
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2000, QualityToolBox.com, LLC, all rights reserved
Performance Excellence Manufacturing
Category Type of Waste Methods Focus Points Principle Desired
of Waste Waste Reduction Worksheets Results
Approach
People Layout Standard Work Sheet
Labeling (SWS) High
Processing Standard Work Tools/parts Time Observation efficiency
arrangement Form and output
Workplace Workplace Work Instructions Standard Work work areas
Motion Management Organization Efficiency Combination Sheet that are safe
Skills training (SWCS)
Kaizen TAKT time Work Load Balancing
Waiting Sheet (WLBS)
Shift meetings
cell/area teams Work Load Balancing
Visual displays Sheet
Kaizen Target Sheet
Kaizen Action Sheet
Quantity Kanban Work balance SWS
Inventory WIP location & SWCS What You
Just in Time Leveling amount WLBS Need
Making too Kanban types Kanbans
much SMED Lot sizes Production Capacity When You
Changeover analysis by Process Need It
Moving Preventive TPM analysis TPM Scheduling
things Maintenance Sheet
Quality Automated SWCS
Detection assistance Error Proofing Action
Fixing defects Error Fixture Sheet Desired
Proofing Warning modifications Error Proofing “To Quality
Successive checks Do” List
Prediction Photocells, Skills Training Matrix
templates, etc.
Prevention Cross training
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2000, QualityToolBox.com, LLC, all rights reserved
1997 Plant of the Year
Industry Week
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2000, QualityToolBox.com, LLC, all rights reserved
Performance Excellence:
Expanding the Strategy through Kaizen
Introduction
Wastes elimination
Kaizen Methodology
Integrated Improvement Strategy
Kaizen Project Examples
32
2000, QualityToolBox.com, LLC, all rights reserved
Kaizen/CPI
A STRATEGY FOR PERFORMANCE
EXCELLENCE
33
2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Project: ISO Hardcopy Procedures Elimination
an Office Process Example
Background:
ISO Policy and Procedures are currently on the company web site.
Hardcopy sets of policy and procedures are also mailed to 95 remote
facilities and distributed to 40 locations within Corporate
Headquarters.
Kaizen Project:
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2000, QualityToolBox.com, LLC, all rights reserved
Current Process:
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Project: ISO Hardcopy Procedures Elimination
Action Plan:
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2000, QualityToolBox.com, LLC, all rights reserved
Improved Process:
1. Outside vendor prints 40 sets of
ISO Policy & Procedures manuals: $889
(for facilities not able to access web site procedures
and eight extra sets)
2. 32 sets of manuals mailed (Fed Ex) to facilities
beyond Corporate Headquarters. $18 /set x 32 sets = 576
$1,465
updated twice per year x 2 = $2,930
(current cost) $9, 420 - (improved cost) $2,930
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Project: ISO Hardcopy Procedures Elimination
Ongoing Continuous Improvement
Action Plan:
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen/CPI
A STRATEGY FOR PERFORMANCE
EXCELLENCE
Kaizen Project:
Color Key - Optimize Press Capability
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2000, QualityToolBox.com, LLC, all rights reserved
Color Key - Optimize Press Capability
Dec. 6 - 10, 1999
Team members: Objectives:
Herkie Hill (Team Leader) Reduce WIP by 70%
Derick Fultz (Sub- team leader) Improve throughput by 40%
Lee Salsberry Reduce backlog by 50%
Carolyn Oliver Reduce leadtime by 5 days
Phylis Dancy Identify (5) 5S improvements
Marvin Bell Train operators on all shifts
Lueontine Smith Work hard and have fun
John Whittington
Dave Hensley (Consultant)
Hosea Foster
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Project: Color Key Press Optimization
Background
Color Key area currently has 14 days of WIP in front of the 4
press operations. The presses are operated on 3 shifts, 5 days per week. The lead
time for these products is approximately 4 weeks.
Kaizen Project
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2000, QualityToolBox.com, LLC, all rights reserved
Current Process of S. Tai Press:
1. Current production average = 118 pcs/hr for a cost of .09 cents per piece
66
15
60 Tool Change
210
90 Clean Up
Breaks
Lunch
Run Time
990 Unaccounted Time
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Project: Color Key Press Optimization
Action plan:
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2000, QualityToolBox.com, LLC, all rights reserved
SET UP TIMES
Machine: S. Tai Start Date: 12/8
Target: 25 % Improvement
12
11:38
Minutes
1 2
Observation Number
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2000, QualityToolBox.com, LLC, all rights reserved
Improved Process of S. Tai Press:
1. Improved production average = 179 pcs/hr for a cost of .06 cents per piece
132 60
90 Tool Change
Clean Up
Breaks
Lunch
Run Time
Unaccounted Time
1119
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2000, QualityToolBox.com, LLC, all rights reserved
Kaizen Project: Color Key Press Optimization
Action Plan
:
1. Create daily review panel of pacer board to help resolve daily problems
in a timely manner. Include maintenance, planning, supervisors and KPO. (1/24)
2. Install 2nd counter on press to help maintain daily output numbers. (12/31)
4. Add yellow and red lights to press for visual notice of downtime. (12/14)
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2000, QualityToolBox.com, LLC, all rights reserved
A Key Strategy In Pursuit
Of World Class
Performance
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2000, QualityToolBox.com, LLC, all rights reserved