Bill Sorel Process Improvement Portfolio Founder and Senior Advisor of TriQuest LLC.
Multi-company Project Management applied to Manufacturing Improvement Improving Business Performance...
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Transcript of Multi-company Project Management applied to Manufacturing Improvement Improving Business Performance...
Multi-company Project Management applied to
Manufacturing Improvement
Improving Business Performance
Team Implementers, LLCCopyright © 2009
Team Implementers, LLC___________Multi-company Management Solutions
MPM2 Improvement Process Vision
• Improvement Enhancement Project that is highly flexible & integrates the following :– Multi-company Project Management– Equipment Supplier Expertise– Continuous Improvement Experiences– DMAIC improvement methodology– OEE metrics
Team Implementers, LLC___________Multi-company Management Solutions
MPM2 Improvement Categories
• Availability– Reduce Breakdowns
– Reduce Changeover Time (Stack, Coil, Die)
– Minimize Adjustments
• Quality– Defect Reduction
– Minimize Rework
– Reduce Start up Impact
• Performance– Speed Optimization
(Product mix)
– Reduce Idle Time
– Eliminate Minor Stoppages
• Equipment Upgrades– Functionality
– Performance
– Reliability
Team Implementers, LLC___________Multi-company Management Solutions
MPM2 Process - Core Ingredients
• Leadership Team
• Measurement Team
• Improvement Teams– Cross-Functional– Targeted Goal & Timeframe– Matched to Customer resources– Integrated with Customer equipment access
Team Implementers, LLC___________Multi-company Management Solutions
MPM2 Process Outline• Opportunity Assessment -Conducted jointly • Environmental Assessment – Performed by Assessor • Contract with Customer to Implement MPM2
• Leadership Team Formation – MPM2 Awareness, Plan Measurement Team• Measurement Team -Formation and measurement of current state• Leadership Team Improvement Planning - Set Goals, Organize
Improvement Teams• Multiple Improvement Teams (simultaneous, overlapping, or sequential)
1st on site event – Analyze & make improvementsHomework – Complete assignments from 1st event2nd on site event – Verify, adjust, standardize improvementsFinal Homework – Complete training, incorporate on other shifts, etc.
• Leadership receives report outs from each improvement team event• Validation – Measurement Team validates results over specified time• Leadership Close Out - Summarize results and lessons learned
Generic MPM2 Process Gantt Chart
Team Implementers, LLC___________Multi-company Management Solutions
Process Activity
MPM2 Timeline
Strategic AssessmentOpportunity
Environmental
Contract Agreement
Leadership Formation
Measurement Team
Improvement Planning
Improvement Team AEvent I
HomeworkEvent II
Improvement Team BEvent I
HomeworkEvent II
Final Homework
Measurement/Validation
Leadership Close Out
31 32
Calendar Weeks27 28 29 3023 24 251 2 3 4 1210 2619 20 21 225 6 7 8 9 11 17 1813 14 15 16
Team Implementers, LLC___________Multi-company Management Solutions
Strategic Assessment Purpose/Structure
• Protect Participants from investing in a process that does not achieve results.
• Three Part Strategic Assessment process Part 1 Scope – Define operations to be improved Part 2 Opportunity - Determine gap between
engineered & actual performance; Verify demand for increased capability.
Part 3 Environment - Determine organization fit to implement the MPM2
• Completely confidential
Team Implementers, LLC___________Multi-company Management Solutions
Part 2 - Opportunity Assessment
• Ideal capacity assumes following:– Zero breakdowns– Zero defects & rework– Optimum operating speeds, feeds, set up, etc.
• Ideal capacity for specified period determined by equipment supplier based on design/use.
• Current state determined from actual production records for specified period.
• Opportunity determined by finding the difference between ideal and current state capacity.
• Demand forecast reviewed to insure utilization of new capacity created by improvements.
Team Implementers, LLC___________Multi-company Management Solutions
Part 3 - Environmental Assessment
• Evaluates (8) parameters– Supportive Leadership - Continuous
Improvement
– Effective Teams - Basic PM Process
– Standardized Procedures - Flexible Work Rules
– Work Place Organization - Willingness to Learn
• Highly subjective over 24-36 hour period
• Uses P-I-F rating for each parameter.
• If any parameter fails, MPM2 process is delayed until parameter improves to I of P.
Team Implementers, LLC___________Multi-company Management Solutions
MPM2 Process Benefits
• Compliments existing systems• Incorporates existing improvement ideas• No disruption of existing teams or processes• Utilizes short term cross-functional teams
with a targeted goal and event timeframe• Team resources matched to manufacturing• Events are integrated with equipment access
Team Implementers, LLC___________Multi-company Management Solutions
MPM2 Process Benefits (cont’d)
• Consolidates Customer & Supplier experiences
• Increases focus on improvement efforts
• Sets clear priorities & high level decisions
• Applies PM & Lean tools/techniques
• Focuses engineering expertise on improvement
• Leadership links all stakeholders
• Double Digit OEE improvements