NPM Metrics
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Transcript of NPM Metrics
ACTIVITY DEPT
Gate 0 : Engagement and Approval
TO BE TRACKED
Plant Facilities
HR
3P Team
PPC
Work Instructions Production
PED/FACILITY PLANNING
Producibility Analysis (Product
and Process Development
Practices)
Engineering & Quality
Personnel Certification
Manufacturing Planning and Scheduling
Pre-Production Planning activities
Production Control
Manufacturing Management
Manufacturing Engineering
Vendor Delivery SCM
QMS
IE
HR
QA
SQA
QA
Software Issues IT
QA
SCM
Material Management
Tooling/Test Equipment
TOOLING, ENGINEERING
& QUALITY
Work Measurement
Engineering & Quality
Schedule Performance
Project Management
Scrap, Rework and Repair (SRR)
Industrial Engineering
Manpower/Training/Labor
Relations
Quality Assurance
Supplier Quality Assurance
Metrology/Variation Reduction
Non-Confirming Materials
Manufacturing Processes and
Control
Engineering & Quality
Manufacturing Stress Screening
Engineering & Quality
Subcontractor Management and
Selection
Manufacturing Technology
Engineering & Quality
Production
IT
IT
Low Rate Initial Production
(LRIP)
Modeling and Simulation
Product Data Management
(PDM)
Gate 0 : Engagement and Approval
METRICS Daily Weekly Monthly Quarterly PMR Annual
Gate 1 : Concept Development
TO BE TRACKED METRICS Daily
• Plant Security• Plant Capacity
•Approvals Regulatory/Statuatory/Legal Bodies• Identify Plant Layout plan
• Identify Critical and scarce materials• Alternates for critical materials or processes identified.
• Cost projections•List of subcontractors required
•Factory layout with Emergency Exit identification• facilities adequacy to support production Additional
requirements if any• facilities shared
• list of schedules established for Plant.
• plant layout optimization
Activities to facility completion (Planned Vs Actual )
Gate 1 : Concept Development
Weekly Monthly Quarterly PMR Annual
Gate 2 : Pre-Production Readiness
TO BE TRACKED
Fabrication & Installation of Tooling (Plan vs Actual)
Technical Data Transfer Status
List of Equipment & spares. List of critical spares, ROI Depvelopment of Equipments, Life cycle estimation of Plant machinery with hours of usage and years.
Number of design, non-design and support tools identified and quantified from customer
Design data transfer from Customer to TASL (Planned Vs Actual)
MBOM Creation Plan vs Actual
AOS / MOS Creation & signoff Plan vs Actual
Configuration Change implementation received vs actual
Parts digitization Plan vs Actual
Production manpower planning
Standard Tools requirements as per work content (% Completion for each AOS/ MOS)
Production Master Scheduling
Document preparation Plan vs Actual
Raw material availability (Plan vs Actual)Vendor Management tracking
NA
Part wise production readiness Plan vs actual
Materials Management (Raw material , Composites, Tooling) PO issue Plan Vs Actual
Expenditure - Budget Vs Actual
Required Approvals (Planned Vs Actuals)
Manpower availability Plan vs actualTraining Plan vs Actual
PMR action items Tracking Plan Vs ActualQuality Certifications (EASA) Plan vs Actual
Kaizen Newspaper SummaryRisk Identification & Mitigation Plan
IT Systems & softwares (ERP, Collaboration Center etc) Identification & Implementation - Plan Vs Actual
IT Architecture (Severs / LAN / Wifi/ Laptops & Desktops/ Printers/ Attendance Recording) Implementation - Plan Vs Actual
MBOM CreationEngineeirng X-Mas tree creation
Process Mapping
Gate 2 : Pre-Production Readiness
METRICS Daily Weekly Monthly
Fabrication & Installation of Tooling (Plan vs Actual)
Activities to facility completion (Planned Vs Actual), Breakdown Analysis Reports, Life cycles & ROI Estimation of Machinery
Gate 2 : Pre-Production Readiness Gate 3 : FAI & Production Induction
Quarterly PMR Annual TO BE TRACKED
• list of schedules established
• plant layout optimization • idle time of any euipment •breakdown analysis and time
recorded
MOS Creation & signoff Plan vs Actual
§5S Activities Initiation & Implementation plan
§Crew Load Charts (Plan Vs Actual)
Cell wise tracking
Crew Load Charts
Recovery Plans (If any)
Configuration Change implementation received vs actual
§Weekly Reviewing & Reporting of Master Schedule (Planned vs Actual)
Production Master Scheduling
Shipset wise manhours Vs target based on learning curve
FAI Document Preparation (Plan vs Actual)
NC & DR volumeDR Ageing & Closure Tracking
Raw material availability (Plan vs Actual)
Manhours planned Vs ActualCycle Time Planned Vs ActualMetrics on On-Time-Delivery
Production Status at each work station AOS burn (Planned Vs Actual)
SQAR trend at each work stationEnergy Consumption
Attendance
Materials Management (Raw material , Composites, Tooling) PO issue Plan Vs Actual
Plan Vs Actual AOS / MOS completion at each work center
Variance Vs the Master Schedule & Recovery Plan if applicable
Process Compliances
Expenditure - Budget Vs ActualShipset wise profitability
Required Approvals (Planned Vs Actuals)
Skill Matrix
EH & S ScorecardSafety score
Consumables consumption/Extra hardware consumption
Gate 3 : FAI & Production Induction
METRICS Daily Weekly Monthly Quarterly PMR Annual
Activities to facility completion (Planned Vs
Actual ) No of Breakdowns
Gate 4 : Production Ramp Up & Stable State
TO BE TRACKED METRICS Daily
Preventive Maintainance Plan vs Actual `
Improvement initiatives (Plan Vs Actual)
Configuration Change implementation received vs actual
§Efficiency & Productivity Report; Improvement Initiatives
§Monitoring Learning Curve
§Value Stream Mapping Implementation ( Plan Vs Actual)
§Reporting benefits of Improvement initiatives
§5S Activities Initiation & Implementation plan Audit Compliance
§Productivity, Efficiency Reporting
§Skill Mapping & Gap Identification
§Time Study (VA & NVA), MOST & Method Study for Manpower requirement
Production Master Scheduling
Crab Trand
DR Trend
NC & DR volumeDR Ageing
Material Shortage (N+5 shipets / 2 months SS)
Risk assessment score for 5 Shipsets minimum (Detail parts)Open/Pending PRs & PR to PO ageing
% Procurement under LTALogistics Cost per SS
Material Consumption – AOP vs. ActualsInventory tracking (RM/FG/ Inprocess) (Dead / Slow moving)
Inventory Turns @ no of MonthsVendor Ratings
Supplier Rationalization Payment Terms
Cutting plan to m/c shop Plan vs actual
Expenditure - Budget Vs Actual
Fast Track Career Program
Improvement initiatives (Plan Vs Actual)
Gate 4 : Production Ramp Up & Stable State Gate 5: LESSONS LEARNT & CLOSURE
Weekly Monthly Quarterly PMR Annual METRICS Daily
Preventive Maintainance Plan vs Actual
TO BE TRACKED
Gate 5: LESSONS LEARNT & CLOSURE
Weekly Monthly Quarterly PMR Annual
List of Events§First revisiting of Man-hours estimation based on inputs from ME/Business Case & master schedule requirements
IMS Preparation3P & Facility Footprint FinalizationValue Stream Map (Depicting Uni-directional flow)Make and Buy Analysis EH& S requirements identification3P1 Event conducted during week of October 10Detailed facility layout developedEquipment list validatedData transfer completedJV site approach road clearing and leveling work completeJV hiring and talent development initiatedMOS development initiated, tooling and raw material RFQs issuedJV closing date TBDIndustrial license approval pendingINTEGRATED MASTER SCHEDULE
§First revisiting of Man-hours estimation based on inputs from ME/Business Case & master schedule requirements
Detail Part ManufacturingGate 2 : Pre-Production Readiness
Facility & Maintenance
Tooling
Technical Data Transfer Status
MBOM Creation Plan vs ActualMOS Creation & signoff Plan vs Actual
Parts digitization Plan vs Actual
IE
Production manpower planning
Quality Document preparation Plan vs Actual
SCM
Activities to facility completion (Planned Vs Actual )
Number of design, non-design and support tools identified and quantified from customerFabrication & Installation of Tooling (Plan vs Actual)
ME & Configuration / Engineering Design data transfer from Customer to
TASL (Planned Vs Actual)Standard Tools requirements as per work content (% Completion for each AOS/ MOS)
Configuration Change implementation received vs actual
Production Master Scheduling
Materials Management (Raw material , Composites, Tooling) PO issue Plan Vs Actual
Vendor Management tracking
PPC NA
Production
Finance Expenditure - Budget Vs Actual
Legal & Compliance
HR Manpower availability Plan vs actualTraining Plan vs Actual
Raw material availability (Plan vs Actual)
Part wise production readiness Plan vs actual
Required Approvals (Planned Vs Actuals)
IT
EH & S
Admin
Program
Kaizen Newspaper SummaryRisk Identification & Mitigation Plan
MBOM CreationEngineeirng X-Mas tree creationProcess Mapping
IT Systems & softwares (ERP, Collaboration Center etc) Identification & Implementation - Plan Vs Actual
IT Architecture (Severs / LAN / Wifi/ Laptops & Desktops/ Printers/ Attendance Recording) Implementation - Plan Vs Actual
TOP / Continuous Improvement
PMR action items Tracking Plan Vs Actual
Quality Certifications (EASA) Plan vs Actual
Assembly Daily Weekly Monthly Quarterly PMR AnnualGate 2 : Pre-Production Readiness
Y
Technical Data Transfer Status
MBOM Creation Plan vs ActualAOS Creation & signoff Plan vs Actual
Parts digitization Plan vs Actual
Production manpower planning
Document preparation Plan vs Actual
Activities to facility completion (Planned Vs Actual )
Number of design, non-design and support tools identified and quantified from customerFabrication & Installation of Tooling (Plan vs Actual)
Standard Tools requirements as per work content (% Completion for each AOS/ MOS)
Configuration Change implementation received vs actual
Production Master Scheduling
Materials Management (Raw material , Composites, Tooling) PO issue Plan Vs Actual
Expenditure - Budget Vs Actual
Manpower availability Plan vs actualTraining Plan vs Actual
Cell / Jig wise production readiness Plan vs actual
Required Approvals (Planned Vs Actuals)
Kaizen Newspaper Summary
IT Systems & softwares (ERP, Collaboration Center etc) Identification & Implementation - Plan Vs Actual
IT Infrastructure (Severs / LAN / Wifi/ Laptops & Desktops/ Printers/ Attendance Recording) Implementation - Plan Vs Actual
Quality Certifications (EASA) Plan vs Actual
Detail Part Manufacturing Assembly Daily WeeklyGate 3 : FAI
MOS Creation & signoff Plan vs Actual AOS Creation & signoff Plan vs Actual
§Crew Load Charts (Plan Vs Actual)
Cell wise tracking
Crew Load ChartsRecovery Plans (If any)
NC & DR volume NC & DR volumeDR Ageing & Closure Tracking DR Ageing & Closure Tracking
Activities to facility completion (Planned Vs Actual )
Activities to facility completion (Planned Vs Actual )Preventive Maintainance Plan vs
ActualPreventive Maintainance Plan vs Actual
Fabrication & Installation of Tooling (Plan vs Actual)
Fabrication & Installation of Tooling (Plan vs Actual)
Configuration Change implementation received vs actual
Configuration Change implementation received vs actual
§Weekly Reviewing & Reporting of Master Schedule (Planned vs Actual)
§Weekly Reviewing & Reporting of Master Schedule (Planned vs Actual)
Production Master Scheduling Production Master Scheduling
§5S Activities Initiation & Implementation plan
Shipset wise manhours Vs target based on learning curve
FAI Document Preparation (Plan vs Actual)
FAI Document Preparation (Plan vs Actual)
Materials Management (Raw material , Composites, Tooling) PO issue Plan Vs Actual
Materials Management (Raw material , Composites, Tooling) PO issue Plan Vs Actual
Detail parts availability (Plan vs Actual)
Manhours planned Vs Actual
Cycle Time Planned Vs ActualMetrics on On-Time-Delivery
Production Status at each work station
AOS burn (Planned Vs Actual)
SQAR trend at each work stationEnergy ConsumptionAttendance
Process Compliances
Expenditure - Budget Vs Actual Expenditure - Budget Vs ActualShipset wise profitability
Skill Matrix
Raw material availability (Plan vs Actual)
Plan Vs Actual AOS / MOS completion at each work center
Variance Vs the Master Schedule & Recovery Plan if applicable
Consumables consumption/Extra hardware consumption
Required Approvals (Planned Vs Actuals)
Required Approvals (Planned Vs Actuals)
EH & S Scorecard EH & S ScorecardSafety score
Monthly Quarterly PMR Annual Detail Part ManufacturingGate 4 : Ramp Up & Stable State
§Monitoring Learning Curve
§Productivity, Efficiency Reporting§Skill Mapping & Gap Identification
Crab Trand
DR TrendNC & DR volumeDR Ageing
Preventive Maintainance Plan vs Actual
Improvement initiatives (Plan Vs Actual)
Configuration Change implementation received vs actual
§Efficiency & Productivity Report; Improvement Initiatives
§Time Study (VA & NVA), MOST & Method Study for Manpower requirement
§Value Stream Mapping Implementation ( Plan Vs Actual)
§Reporting benefits of Improvement initiatives
§5S Activities Initiation & Implementation plan Audit Compliance
Production Master Scheduling
Material Shortage (N+5 shipets / 2 months SS)
Open/Pending PRs & PR to PO ageing
% Procurement under LTALogistics Cost per SS
Inventory Turns @ no of MonthsVendor RatingsSupplier Rationalization Payment Terms
Cutting plan to m/c shop Plan vs actual
Expenditure - Budget Vs Actual
Risk assessment score for 5 Shipsets minimum (Detail parts)
Material Consumption – AOP vs. Actuals
Inventory tracking (RM/FG/ Inprocess) (Dead / Slow moving)
Improvement initiatives (Plan Vs Actual)
Assembly Daily Weekly Monthly Quarterly PMR AnnualGate 4 : Ramp Up & Stable State
Crab Trand
DR TrendNC & DR volumeDR Ageing
Preventive Maintainance Plan vs Actual
Configuration Change implementation received vs actual
Production Master Scheduling
Expenditure - Budget Vs Actual
Improvement initiatives (Plan Vs Actual)