Model Rockets 6 th grade Project Model Rocket Project Overview.
The Foundation for Continuous Improvement: The …...•10-Step QM project implementation •model...
Transcript of The Foundation for Continuous Improvement: The …...•10-Step QM project implementation •model...
The Foundation for Continuous
Improvement:
The Purpose of Pillars
Milliken Performance System
Safety
• Safety is the foundation of the performance system that engages all associates in the uncompromising pursuit of zero incidents.
What
• Foundation that signals the individuals’ personal well-being comes first, and from there creates the elements for a high performance work environment.
Role in the System
• All associates
Who
• Zero incidents, high morale, 100% associate engagement, trust between associates and management
Deliverables How
• Total associate ownership
• Hazards, risks identified
• Steering committees
• Sub-committees
• Use of continuous improvement tools and methods
• Management as a resource and coach
Daily Team Maintenance
• DTM provides operators with the knowledge and skills required to proactively prevent breakdowns and waste caused by accelerated equipment deterioration and abnormalities.
What
• Improved reliability and stability, setting foundation for other pillar improvements
Role in the System
• Operators, technicians, maintenance, production leadership
Who
• Reduction in minor stops, breakdowns, changeover time
DeliverablesHow
• 0: Prepare for Restoration
• 1: Restore, Inspect, Understand
• 2: Identify Deterioration & Implement Solutions
• 3: Establish Cleaning & Lubrication Standards
• 4: Train Operators to Detect/Correct Abnormalities
• 5: Apply Practical Application of Methods
• 6: Standardize DTM Throughout the Location
• 7: Continuously Improve the Process
5S
• Process used to organize and maintain the workplace environment in order to improve efficiency and safety, reduce waste, and eliminate non-value added activities.
What
• Foundational process which establishes the expectations of discipline and overall engagement
Role in the System
• All associates
Who
• Improved safety, reduction in non-value added activities
DeliverablesHow
•Model areas
•Separate
•Simplify
•Systematize
•Standardize
•Sustain
Continuous Skills Development
• A standardized training process to ensure our associates are doing things the right things, the right way, every single time.
What
• Decrease variation within the production systems attributed to training opportunities
Role in the System
• All associates
Who
• Reduction in process variation, turnover, and overall training spend
Deliverables How
• Model areas
• Skills element tree
• Skills assessment
• Associate certification
• Re-training process
• Individual performance measurement
Focused Improvement
• FI provides a logical thinking process which identifies root causes of opportunities in order to reduce / eliminate losses.
What
• FI Planning and FI projects direct and then generate resources to fund the performance system while improving capability of processes, people and reducing loss
Role in the System
• Operators, technicians, maintenance, process improvement leadership, engineering
Who
• Reduction in targeted loss areas, increase in problem-solving confidence
Deliverables
How
• Project approach following the DMAIC methodology
•Define
•Measure
•Analyze
•Improve
•Control (and replicate)
Planned Maintenance
• Combination of preventive, predictive, andzero failure activities. Oversees maintenance schedule, processes, and activities to prevent breakdowns before they occur instead of repairing them after the fact
What
• Foundation for reliability and continuous improvement
Role in the System
• Maintenance technicians, maintenance leadership, engineering
Who
• Reduction in breakdowns and spare parts spend
Deliverables
How
•DTM support
•Lubrication management
•Spare parts management
•Predictive maintenance
•Cost management
•Preventive maintenance
•Skills enhancement
•Zero failure activities
The Advanced Pillars
Building on the Core
Production Control
How
• 7 Step process
•Value stream mapping
•Waste walks
•Improvement projects
•Layered audits
•Demand planning
•Skills enhancement
•Zero failure activities
• Reduce overall system cost through the elimination of waste identified within the system. To align the business offering with manufacturing execution.
What
• Maximization of the velocity of information and material flow through the process/system.
Role in the System
• Supply chain, production leadership, operators, technicians, suppliers, customers
Who
• Improve working capital/inventory, variable conversion cost, capacity utilization, floor space availability, inventory optimization
Deliverables
Quality Management
How
• 10-Step QM project implementation
•model project on model equipment defect
• A systematic methodology to achieve zero quality defects (not just fewer defects) by systematically seeking out, identifying, and eliminating root causes of ALL defects.
What
• Take processes beyond reliability to capability and the quality process from compliance to assurance
Role in the System
• Operators, maintenance, quality assurance, quality leadership
Who
• Reduction in defects, yield loss, waste
Deliverables
Early Equipment Management
• To “design out” losses related to equipment start-up before they occur by utilizing existing measurement data & learnings.
What
• Improved reliability and stability, setting foundation for other pillar improvements
Role in the System
• Operators, technicians, maintenance, production leadership, engineering
Who
• Reduction in start-up time, losses and costs
Deliverables
How
• concept and equipment planning
• equipment design
• manufacture equipment
• preliminary testing
• install equipment
• commission new equipment
• full production implementation
New Product Development
• Cross-functional activity to provide a continuous flow of innovative, new products
What
• To ensure a robust stream of new products into the system that creates value for the company and customer
Role in the System
• Customers, suppliers, business, research, manufacturing, supply chain
Who
• Shortened delivery cycle, high quality zero loss start-ups, meet/beat targeted costs, 100% on-time delivery
DeliverablesHow
• 6 Step Process
• Discovery & concept development
• Product design requirements
• Design for manufacturing
• Adoption & launch
• Scale-up & commercialization
Pillar Relationship Matrix5S DTM CSD PM FI QM PC EEM NPD
5S ● ● ● ● ● ● ● ●
DTM ● ● ● ● ● ● ● ●
CSD ● ● ● ● ● ● ● ●
PM ● ● ● ● ● ● ● ●
FI ● ● ● ● ● ● ● ●
QM ● ● ● ● ● ● ● ●
PC ● ● ● ● ● ● ● ●
EEM ● ● ● ● ● ● ● ●
NPD ● ● ● ● ● ● ● ●
= interaction= major impact on success
Energy
Inventory
Obsolescence
Quality / reworks
Waste
Training
Inspection & Testing
Material Handling
Planning
PM & Cleaning Downtime
Speed Loss
Minor Stops
Start-up / shut down
Change time
Breakdowns
NPDEEMPCQMPMFICSDDTM5S
Energy
Inventory
Obsolescence
Quality /
Waste
Training
Inspection & Testing
Material Handling
Planning
PM & Cleaning Downtime
Speed Loss
Minor Stops
Start-up / shut down
Change time
Breakdowns
5S
Some impactSome impact Medium impactMedium impact Major impactMajor impact Future impactFuture impact
Pillar to Loss Relationship Matrix