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29/04/2018 1 Designing Work Systems for Reliability and Performance Professor Nick Rich Swansea University
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Designing Work Systems for Reliability and Performance
Professor Nick RichSwansea University
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Professor Nick Rich
Professor of Socio-Technical Systems Design at Swansea University
Honorary Associate Professor Warwick Medical School
Chief Industrial Engineer (2012 Olympic and Paralympic Medal Programme)
Co-Founder at the Lean Enterprise Research Centre
With Dan Jones as chief researcher (Lean Thinking)
Toyota Motor Corporation Japan Senior Research Fellow Shingo Prize Examiner
Half Manufacturing and half NHS!
Much of six sigma and quite a lot of lean/operational Much of six sigma and quite a lot of lean/operational Much of six sigma and quite a lot of lean/operational Much of six sigma and quite a lot of lean/operational excellenceexcellenceexcellenceexcellence
• Overly-focused on success and back slapping
• Underdeveloped learning infrastructure
• Heightened sensitivity to quality vs safety and reliability
• Focus on efficiency exclusively and forgetting to make systems that allow workers to be smarter
• Inefficient learning (episodic) which is time consuming and a damaging artefact
• Lack of diversity (focused conformity) in everything but especially involvement of other business departments
• Information & communications filtering
• Reject or excuse early warning signs of quality degradation
• Poor levels of sensitivity and control
• Personal mastery is a joke! We can be little more than sophisticated Taylorism!
• Context is ignored! FMEA is but one example!
Adapted from: Weick and Sutcliffe (2007)
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Basic Discipline SAFETY AND MORALE
QUALITY UP = COST DOWN
DELIVERY UP + QUALITY GOOD = COST DOWN
PROCESS FLEXIBILITY UP = COST DOWN
COST DOWN FOCUS (SCM)
TIME
The Competitive Keys
For Complexity
Exploitation
COST DOWN FOCUS (by Design)
EF
FE
CT
IVE
NE
SS
The One and Only LogicThe One and Only LogicThe One and Only LogicThe One and Only Logic
• Even enlightened leaders are responsible designers
• Hierarchy confers responsibilities
• Grow your business
• Nurture others
• Design Systems
• Build a learning organisation
• Diversify skills whilst making life easier to do
We Design Systems, processes and culturesWe Design Systems, processes and culturesWe Design Systems, processes and culturesWe Design Systems, processes and cultures
Responsibility
and Accountability!
99.9997% good
3.4 PPM defects
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Total Quality
Management
Approach
Lean Production
System Design
Total Productive Maintenance
Approach
Workplace Organisation
CANDO/5S
Visual Management
Teams
Six Sigma
Statistical Process Control
Design of Experiments
Taguchi Methods
Early Equipment Management
Reliability Centred Maintenance
Level Production
Supplier Pull Systems
Cells & Layout
Quick Changeover
Problem-Solving
Problem-Solving Problem-Solving
Autonomous Maintenance
Planned Maintenance
Quality Maintenance
OEE Analysis
Mistake Proofing
Standardised Work
Mistake ProofingMistake Proofing
Brainstorming
Cause and Effect
Pareto
Quality
FocusDelivery
Focus
Cost
Focus
Physical Improvement (Workplace, Materials and Equipment)
Status of work and Performance
(Standardised Work and Information)
Decision Making and Process Situational Awareness
Self-Management Breakthrough Learning Groups
Establishing Roles and Responsibilities (current state and future state)
Cognitive – Multi-Disciplinary Team Working and Value Stream
Management
Levels of Control
Cognitive – Enhanced Decision Making and Empowerment
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ATTENDING
BREAKDOWN
EVENTS
CONDUCTING
ROUTINE
WORK
CORRECTING
PROBLEMS
50%
100%
©Nick Rich 1998
The Engineer’s Real Job
WORKING
TIME
ATTENDING
BREAKDOWNS
CONDUCTING
ROUTINE
WORK
PREVENT
PROBLEMS50%
100%IMPROVEMENT
PROJECTS
©Nick Rich 1998
The VALUE of an Engineer!
WORKING
TIME
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8 TPM Main Pillars
Improve Equipment Effectiveness
Autonomous Maintenance
Planned Maintenance Activities
Quality Of Maintenance
Early Equipment Management
Education & Training
TPM In The Office
Safety & The Working Environment1
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3
4
5
6
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The The The The 6Rs of 6Rs of 6Rs of 6Rs of Operational Excellence & SystemsOperational Excellence & SystemsOperational Excellence & SystemsOperational Excellence & Systems
• Robust by design
• Reliable by operation
• Reactive to error and deviation
• Reviewing with facts
• Reflecting and learning
• Resilient to events
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Designing Work Systems for Reliability and Designing Work Systems for Reliability and Designing Work Systems for Reliability and Designing Work Systems for Reliability and PerformancePerformancePerformancePerformance
Professor Nick [email protected]
Swansea University
