Rapid Site Assessment June 27 2010
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Transcript of Rapid Site Assessment June 27 2010
8 Wastes1. Transportation 2. Inventory 3. Motion 4. Waiting 5. Over processing 6. Over production7. Defects 8. Unused Human Potential
Rapid Site Assessment
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Transportation
2
Definition: Any movement of product that does not add value
Example: Moving parts in and out of storage, movement of parts between processes
Indicator: Batch Production, push production, large storage areas, functional layout
Action to take: One Piece Flow, VSM, Point of use storage
2
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Inventory
3
Definition: Any material or product that is not needed to satisfy the current customer demand
Example: Excess raw materials, work in process, finished goods,
Indicator: Long supplier lead times, lack of visible flow, long setups, no ordering process on shop floor
Action to take: Pull Systems, One Piece Flow, VSM, SMED
3
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Motion
4
Definition: Any movement of people that does not add value
Example: Searching for parts/tools/prints, sorting materials, reaching for tools, lifting parts/boxes
Indicator: Workplace disorganization, poor workstation design, unsafe workspaces, missing items
Action to take: 5S, Hoshin, VSM, Point of Use Storage, Water-Spider
4
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Waiting
5
Definition: Idle time created when material, information, people or equipment are not ready
Example: Waiting for parts, prints, inspection, machines, repairs, information
Indicator: Push production, work imbalance, centralized inspection, high downtime, no visible production plan
Action to take: Work Balancing, SMED, TPM, In process Inspection
5
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Over processing
6
Definition: Any effort that adds no value from the customers viewpoint
Example: Multiple cleaning of parts, over-tight tolerances, paperwork
Indicator: Delays between processes, No DFM process involving employees, No standardized work
Action to take: VSM, One Piece Flow, Standardized Work
6
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Overproduction
7
Definition: Producing more that the customer needs right now
Example: Producing to forecast, producing to avoid setups, batch production
Indicator: Forecast on shop floor, long setups, inventory to cover breakdowns
Action to take: Pull Systems, Work Balancing, Hourly Takt Targets, SMED
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Defects
8
Definition: Any effort to contain, rework or disposition mistakes or errors
Example: Scrap, rework, customer returns, supplier rejects
Indicator: Processes not defined and stable, Poor handling and tracking of rejects/rework, Internal and external defect rates not visible
Action to take: Standardized Work, DM Process, Customer Focus Area, Shop Floor Problem Solving
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Unused Human Potential
9
Definition: Any Losses due to lack of utilization of the entire team in continuous improvement
Example: No cross-functional teams, top-down management, no suggestion programs
Indicator: No Team communication areas, poor understanding of priorities, employee resistance to new ideas
Action to take: 5S, Daily Team Meeting, Suggestion System, QRQC
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Example - Scorecard
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Example - Scorecard