Date post: | 21-Dec-2015 |
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Manufacturing Operating Principles Framework
Human Infrastructure
Standardization
Quality Focus & Robust Processes & Products
Just-In-Time
Continuous Improvement
Policy Deployment
Employee Opinion Surveys
Std Communication Channels
Man Assignments
New Hire Orientation
Group / Team Meetings
Suggestion System
Shopfloor Training Area
Integration of Tasks
Qualification Training Matrix
Safety Regulations
Ergonomic Evaluation
Environmental Protection
Process Support Documentation
Scoreboards
Standard Shift Change Procedure
Quality Gates
Labeling, Marking, & Footprinting
Shopfloor Section Audit
Quality Alerts / Prod. Info. Boards
Quality Alert System / Quality Stop
Certification Audit
Process Audit
Single Point Lesson
Problem Solving / Closed Circuits
Process FMEA
Customer Quality Measurement
Production Planning Schedule
Mixed Loads / Tugger Transport
Withdrawal & Fill-up
One Piece Flow
First-In, First-Out (FIFO)
Single Stage Stock strategy
Stable Customer Demand Rate
5 Step Improvement Process
C. I. Workshop
Leadership
Role Clarity
Employee Involvement & Development
Work Group Organizational Structure
Safe Work Practices & Environmental Awareness
Standardized Methods & Procedures
Visual Techniques / 5S
Quick Issue Detection & Correction
Robust Processes / Products & Preventative Quality Assurance
Customer Focus
Production Smoothing
Pull Production
Continuous Flow Proc.
Customer Demand Rate
Waste Elimination
Enablers Subsystems
H. R. Systems
Joint Commitment
Communication
Training
Core Beliefs & Values
TeamworkInspirationOpenness
CustomerFocus
Agility
Innovation
OPERATINGPRINCIPLES
Process
Focus
Quality
Speed (to market) Excellence
Responsibility
S
afety
Q
uality
D
elivery
C
ost
M
orale
Profitability
Support Processes, Tools, & Measurement Results
Employee Feedback
Employee recognition
Checklists and Monitoring
Group Development Activities
Process Descriptions
On the Job Training
C. I. Implementation Area
Team Leader Roles (as applic.)
Groups, Boards
Cross--Functional Training
Visual Safety Indicators
Refuse / Waste Separation
Standard Work Instructions (SWI’s)
Standard Work in Process (WIP)
Shopfloor Measurement
Standardized Equipment
5S
Quality Feedback Loops
Root Cause Analysis
Boundary samples
Preventative Maintenance
Total Productive Maintenance
Error Proofing
Mistake Proofing
Statistical Process Control (SPC)
Quality Agreements
Quality / Zero Defect Gate
In-Line sequencing
Order Cards
Material Flow Planning
Small Lot Containers
CDR / Cycle time chart
Plan, Do, Check, Act (PDCA)
7 Wastes
5 Why’s
Engineering Change Control
Practice Sharing
MQAS
Quality Policy / Management ReviewBusiness Plan / Assurance SystemPerformance Feedback
Responsibility and Authority
Training
Resources
Use of Cross Functional Teams
Employee Safety / Environmental
Doc & Data Cont / Prod ID & Trace.Process Control / Inspection & TestInsp & Test Stat / Cont of Quality RecordsHandling, Storage, Pkging, PreservationControl of Customer-Supplied Product
Control of Non-conforming ProductCorrective and Preventative ActionStatistical Techniques
Production Part Approval ProcessDesign Control
Preventative Maintenance & Calibration
Contract Review
Delivery (Prod Sched - 1 Piece Flow) Inventory
Quality Planning Purchasing
Cont. Imprv / Corrective & Prev. ActionManufacturing Capabilities
Analysis & Use of Company DataCustomer Satisfaction / Assurance Asses.
Human Aspects
Consumer Feedback:• After purchase surveys• Surveys to potential buyers
Employee Feedback:• Process problems or improvements (lighter robotic arm design)• Integrated into continuous improvement process (Suggestion
box, recommendations to supervisors)• Employee online surveys
Unions:• Union representatives / liaisons to assist employees with problems• Recognition of employees as the most important asset of the company
Human Aspects
Training:• Cross training of employees (varied tasks, flexibility of supervisors)• Floaters (use in assisting with critical tasks, flexibility supervisors for
breaks)• Company closed circuit television in break area (covers company
news, financial updates, new products)• Voluntary participation in continuing education classes
= higher morale
Technological Aspects
Facility Layout:
• Open aisles allow managers to monitor processes and employees
to detect problems
• Reduction of wasted movement (i.e. travel distances)
• Workstation design
Ergonomics:
• Force, frequency and flexion
• Ergo-Arms, foot pads, roller racks, tilt racks, hydraulic tables
• Use of employees in the design phase of manufacturing
Technological Aspects
Material Handling:
• Reduction of component stocks (1 1/2 hour operations) at stations
• Components come in pre-packaged amounts for specific jobs
• Component packages stored in marshaling areas
• Reduce the lifting done by the employees
• Computerized / Wireless acquisition (fork lifts)
Mistake Proofing:
• Color Coding
• Shape Coding
• Bar code scanner for all sub-parts (can track all parts by VIN #)
• Computerized feedback from tools
Technological Aspects
Preventative Maintenance:
• Scheduled services occur at shift changes
• Unscheduled services conduct repairs upon employees request
• Testing Measuring Diagnostics Equipment
System AspectsStandardization:• Standardize work instruction and directions• 5 S’s (Sift, Sweep, Sort, Sanitize and Sustain)• SPC Charts• Preventative Maintenance• Safety (Paint markings, laser indicators)
JIT:• Orders received at the gate trigger each department• Reduction of inventory equates to reduction of storage requirement,
increases working capital, decreases bureaucracy• Increases responsiveness to customers• Temporary bank after human intensive stage
System AspectsComputerized Monitoring:
• Real-time production statistics
• Color coded warning system
• Defects on products are noted and tracked throughout the process
• KUKA camera tracking system
• Computerized check of all options (Huntsville check)
Continuous Improvement:
• Non-Value added activities
• Wastes
Definition of Value Added Activity (VA)• An activity that transforms or changes raw material or information to meet
customer requirements.
Value Added Tests:– The customer must recognize the value (be willing to
pay for it)
– The product must physically change during the process
– The activity must be done right the first time
Definition of Non-Value Added (NVA) Activity• Any activity that does not transform or change raw material or information
to meet customer requirements.
Non-Value Added Tests:– Activities that do not meet all of the three VA test rules
– Some non-value added work may be necessary
Value Added
• Machining
• Stamping
• Assembling
• Designing
• Customer Service
• Analysis
• Painting
• Sealing/Welding
Non-Value Added• Transportation
• Inventory
• Defective material
• Wait Time
• Inspecting
• Testing
• Correcting
• Batching
• Setup
The 7 Wastes1. Product Defects: Defects or repair work
2. Overproduction: Producing too much or too soon
3. Inventory: Excess raw materials or work in process
4. Transportation: Double handling or conveyance of materials
5. Processing: Unnecessary work or processing
6. Waiting: Waiting for parts, materials machines to cycle
7. Motion: Excess walking, bending, or reaching
POLICIESMinimizeFluctuation
Downstream fluctuations must be minimized to reduce the “rippleeffect” on upstream processes.
Implement ShortLead Time
Short lead times are the keys to flexibility, cost reduction, andcustomer satisfaction. Rather than optimizing individual piecesand functions, optimize total throughput.
Eliminate waste Strive to eliminate waste, especially overproduction. In otherwords, do not produce too many, too soon or too fast.
Recognize thelimitations of plans,forecasts, andschedules
Remember that forecasts are necessary evils and plans dochange. Therefore forecast as accurately as possible, recognizethe limitations of forecasts, and plan accordingly. Be prepared torespond quickly to change.
Focus on the actualcondition of the“front lines”
Identify and solve problems when they happen. Capitalize on thecollective knowledge of the team. Utilize team members’knowledge.
Keep it simple andmanageable
Resiliency and flexibility are facilitated by a synchronizedprocess.