4 Process Teams Represent 4 Production plants

instead of Departmental barriers

CHEETA COBRA SMART BLACK EAGLE

Plant Q Plant R Plant S Plant T

Leader Nalin Asanka Dhanuka Mihiruk

Facilitator SAWS CBE GARDG PIR

Member RAJ MN SPCP NCSB

Member SSW DW WACCK LM

Member SS RASR MF SDH

Member CNM SL SPLLG GW

Member NKS

TEAM COMPOSITION -Staff

Position

1st Operation Planning Meeting – January 2010

Joint Operation Centre ( JOC) – Place for Operation

1st Operation Excellence Review Function – Feb. 2010

1st Operation Excellence Review Function – Feb. 2010

What is Lean? Which benefits outcome from Lean to us ? Lean Induction for all factory employees with the participation of ICEU members

Start of 2nd LEAN Project Team Started a training program to educate both staff & employees about basic Lean Tools

Start of 2nd LEAN Project Team After the 1st Lean Training, participants were divided in to 10 Lean Teams

Start of 2nd LEAN Project Team Before start main project, Find the solutions for small problems (Abnormalities) identified by the Team members

3 Lean Training programs, 20 Lean Teams, 200 Educated Employees about Lean Tools

Operation Planning Meeting (OPM)

ROR – Real time Operation Review

Mid month Review Meeting (MRM) No. Objective Target Achievement Varience

1 OEE %

1.1 AR %

1.1.1 Total Down time ( hrs.)

1.1.2 Engineering Down time (hrs.)

1.1.3 Other Down time (hrs.)

1.2 PR %

1.3 QR %

1.3.1 D1 %

1.3.2 D2 %

1.3.3 Scrap & Rejects %

1.3.4 Grade II %

1.3.5 Single Hand %

1.3.6 Excess Production %

2 Glove Standards

2.1 Glove Length (no of days out of specs.)

2.2 Glove Thickness (no of days out of specs.)

2.3 Glove Weight (no of days out of specs.)

3 Reserved compound

3.1 Compound Unloaded (kg)

3.2 Compound Blended (kg)

4 Former Breakages

4.1 No of Former Breakages

4.2 No of Craked Formers

5 Kaizen

5.1 No of Kaizen Identified

5.2 No of Kaizen Completed

6 Abnormality

6.1 No of abnormalities identified

6.2 No of abnormalities completed

6.3 No of balance abnormalities to do

7 Last PDT review meeting minutes

8 C & P Projects

Monthly KPIs for MRMAction

No. Objective Target Achievement Varience

3 Reserved compound3.1 Compound Unloaded (kg)

3.2 Compound Blended (kg)

4 Former Breakages

4.1 No of Former Breakages

4.2 No of Craked Formers

5 Kaizen5.1 No of Kaizen Identified

5.2 No of Kaizen Completed

6 Abnormality6.1 No of abnormalities identified

6.2 No of abnormalities completed

6.3 No of balance abnormalities to do

7 Last PDT review meeting minutes

8 C & P Projects

Monthly KPIs for MRMAction

Monthly Operation Excellence Review

Sharing Experience taken from monthly Operation

Monthly Operation Excellence Review

Awarding the Winners of the monthly Operation

Monthly Operation Excellence Review Opportunity to build up good relationship between staff &

employees

Monthly Operation Excellence Review Opportunity for all employees to exhibit their talents in

front of management & employees

Monthly PDT Review Review the Progress of Month DOS Operation Excellence

program to the Group Top management by Team members

in Every month.

During 2011 & 2012 DOS Operation ,

• Implementad 288 Nos. of Kaizens

• Identified 8,460 Abnormalities and

Corrected 7,206 from them

• Thousands of 6S Improvements

• 209 nos. Of Why Why and Fish bone Analysis

• Hundreds of Projects based on 10 Steps Approach directed on PQCDSM improvements

• Create the new “Process approach culture” by changing the departamental bariers based on lean concepts.

Achievements

• OEE increased from 64% to 86.5% from January

2010 to February 2013.

Achievements