At the conclusion of this session, attendees will be able to: Leverage fundamental tools to identify opportunities for improvements

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2 At the conclusion of this session, attendees will be able to: Leverage fundamental tools to identify opportunities for improvements Explain the difference between the 5 different type of Kaizens Create a prioritized project pipeline

3 I see fires everywhere Where do I start?

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6 2015 Fabrice Bouchereau

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8 2015 Fabrice Bouchereau

9 POINT Kaizen MINI Kaizen Kaizen BLITZ FLOW Kaizen SUPPLY CHAIN Kaizen

10 Visual communication tools Based on traditional Kanbans principles Visible to all levels of employees within the organization Used to coordinate project selection and execution based on complexity and return on investment

11 KAIZEN KANBAN FMEA I/O DEFINITION SIPOC VA / NVA PROCESS MAP

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13 Receive order Prepare Traveler Cut Tubes Weld Tubes Sandblast Frame Sand Frame Paint Frame Apply Clear Coat DOCUMENTATION PROCESS FRAME MAKING PROCESS PAINT PROCESS Install Brakes Install Gears Install Seat Mount Tires On Rims Install Rims on Frame Inflate Tires Add Protective packaging Box Bicycle COMPONENT INSTALLATION PROCESS WHEEL INSTALLATION PROCESS PACKAGING PROCESS

14 Value Adding Step (VA) Non-value Adding Step (NVA)

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16 Receive order Prepare Traveler Cut Tubes Weld Tubes Sandblast Frame Sand Frame Paint Frame Apply Clear Coat DOCUMENTATION PROCESS FRAME MAKING PROCESS PAINT PROCESS Install Brakes Install Gears Install Seat Mount Tires On Rims Install Rims on Frame Inflate Tires Add Protective packaging Box Bicycle COMPONENT INSTALLATION PROCESS WHEEL INSTALLATION PROCESS PACKAGING PROCESS

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18 Imput Suppliers Inputs Operator Receive order Prepare Traveler Cut Tubes Weld Tubes Sandblast Frame Sand Frame Paint Frame Apply Clear Coat DOCUMENTATION PROCESS FRAME MAKING PROCESS PAINT PROCESS Owner Install Brakes Install Gears Install Seat Mount Tires On Rims Install Rims on Frame Inflate Tires Add Protective packaging Box Bicycle Trigger COMPONENT INSTALLATION PROCESS WHEEL INSTALLATION PROCESS PACKAGING PROCESS Outputs Customers Output Phone:

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20 Line # Severity Occurrence Detectability Risk Category Line # Severity Occurrence Detectability Current Failure Mode Controls New Failure Mode Controls 1 Truck Arrives at Gate: Truck Arrives at Gate: Guard Not meeting standard PPE standards, loading checks for PPE and ATS showing standards, ATS required for ALL shipment is valid and safe for entry shipments, ATS ensures parts and has an appointment. are ok; scheduling has been done. "ACCEPT NO DEFECTS" 0 Rejected truck turns up at dock Check for ATS at dock Truck arrives at dock. Check Incorrect or missing Paperwork Truck arrives at dock. Scan ATS, Forget to scan Electronic verification, Scan Documents electonically flagging PO items to code on ATS. Bar code be received to mobile scanner tool includes all part number, po, and serialization information Dock is blocked with other trucks Dock is blocked with other trucks All Devlieries are scheduled Unload Truck to staging area Fail to unload parts Unload Truck to staging area Fail to unload parts Unsafe load Q Unload unsafely Training and licensing Parts already damaged or Q Parts already damaged or Packaging standards enforced improperly protected improperly protected Wrong Pallet Size? Wrong Pallet Size Written and enforced standard for acceptable pallets Driver not wearing proper PPE? Driver not wearing proper PPE PPE standard enforced at gate Unload unsafely Training and Unload unsafely Training and licensing licensing Forktruck not available Forktruck not available Forktruck dedicated for unloading trucks Area Full Area Full All Devlieries are scheduled; adequate space allocated; high material "velocity" Large part delivered with out notice, Large part delivered with out All Devlieries are scheduled; lack crane or space notice, lack crane or space adequate space allocated 4 Verify Part numbers, EQ Fail to recognize problem Scan Item, electronically verifiying Forget to scan Electronic verification numbers, and tag numbers PN, equipment and serial numbers, with Pallet number Receive PO Item Part improperly oriented on pallet Part improperly oriented on pallet Standard for location of bar codes; include in Q651 with part orientation requirements 5 Place paperwork in clerk Forget to put in basket X ELIMINATED Done electonically, 0 basket automatically 6 Get paperwork and check Misread/mistype numbers X ELIMINATED Done electonically, 0 part numbers to SAP automatically 7 Transact to receive item in Problem PO X ELIMINATED Done electonically, 0 SAP automatically Entry Error Fail to transact Check if material is dock to Fail to communicate correct status X ELIMINATED Done electonically, 0 stock automatically 9 Inspect documents to ensure Fail to find defect X ELIMINATED Eliminated thru ATS 0 they are correct 10 Scan Documents into Fail to Scan, Can't find docs later X ELIMINATED system Poor Scan, Can't find docs later Move part to next location Take part to wrong location Move part to next location (W/H or Take part to wrong location Scan into location, Suppliers (W/H or inspection) inspection) required to arrange parts by desintation location (no repalletization required) Location is full Location is full Need to fix this! Fabrice Bouchereau Item not moved Item not moved Electronic Verification, Dedicated fork truck for unloading trucks Inspect Part and transact in SAP Unclear specifications, supplier Inspect Part and transact in SAP Fails inspections Inspection Flag is on the in transit failiure; damage material master when required, and can only be cleared by completing the Recvg inspection process No tools No tools Dedicated and controlled tools and guages for process; 5S Changing priorities, expeditiers Hot Tag Changing priorities, expeditiers FIFO / Hot Tag Reinspecting Parts for engineers, Reinspecting Parts for engineers, FIFO others others Reshuffling pallets Reshuffling pallets FIFO for inspection, Pallet jacks and lift tables or dedicated fork truck, supportive layout, 5S Doumentation incomplete NFM 0 Part does not need inspection NFM 0 13 Move part to next location (W/H staging) 14 Inspect pallet for proper protection, and paperwork 15 Determinine if part has location defined in warehouse, if not, define location for material Take part to wrong location Move part to next location (stock Take part to wrong location Scan into location location desinated by scanner, or All locations defined on material W/H staging area) master. Item not moved Item not moved Electronic Verification Bad Pallet, not preped properly, no Paperwork is eliminated 0 X ELIMINATED paperwork Waiting on previous transaction to X ELIMINATED Done automatically, clear electronically

21 Failure Mode Potential Effect / Consequences Frequency Severity Detectability

22 Phone: Phone: Imput Phone: Phone: Phone: Phone: Phone: Phone: Phone: Imput Imput Start Failure Mode Failure Mode Potential Effect / Consequences Suppliers Inputs Operator Suppliers Inputs Operator Failure Mode Failure Mode Potential Effect / Consequences Frequency Severity Detectability Potential Effect / Consequences Owner Trigger Potential Effect / Consequences Severity Detectability Frequency Frequency Severity Detectability Owner Trigger Frequency Severity Detectability Failure Mode Outputs Outputs Potential Effect / Consequences Customers Customers Frequency Severity Detectability Output Output Imput Imput Imput Input Imput Imput Suppliers Suppliers Suppliers Suppliers Suppliers Suppliers Suppliers Inputs Inputs Inputs Inputs Inputs Inputs Inputs Operator Operator Operator Operator Operator Operator Operator Owner Owner Owner Owner Owner Owner Owner END Trigger Trigger Trigger Trigger Trigger Trigger Trigger Outputs Outputs Outputs Outputs Outputs Outputs Outputs Customers Customers Customers Customers Customers Customers Customers Output Output Output Output Output Output Output Failure Mode Failure Mode Failure Mode Potential Effect / Consequences Potential Effect / Consequences Failure Mode Potential Effect / Consequences Frequency Severity Detectability Frequency Severity Detectability Failure Mode Potential Effect / Consequences Frequency Severity Detectability Potential Effect / Consequences Frequency Severity Detectability Frequency Severity Detectability

23 Few Vital Task 20% of time 80% Results Many Trivial Task 80% of Time 20% results

24 Who is affected by the issue or who discovered the issue/trend? What is the problem? When did it occur (date, time, etc.)? Where the problem took place? Extent or magnitude of the situation?

25 Payoff 25 Implement Challenge Possible Kill Difficulty

26 Payoff Duration Score Ressource Type Score High Short 1 Individual 1 60 Medium 5 Localize team 5 Long 9 Cross functional team X 20 Low Easy Hard Delay Score Impact magnitude Score Implementation Difficulty Long Term 1 Localized 1 Mid Term 5 Department Wide 5 Short Term 9 Plant Wide 9

27 Waste Tool location Ergonomics Poke Yoke Workflow Cell Layout Line balancing 5S Team forms for specific purpose or the event Cross Functional Teams Issues System Issues Part-time representative s from other companies

28 Benefit High Kaizen Blitz Supply Chain Kaizen 50 Mini Kaizen Flow Kaizen Point Kaizen Only execute if mandatory Low Easy Hard Implementation Difficulty

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31 POINT Kaizen MINI Kaizen Kaizen BLITZ FLOW Kaizen SUPPLY CHAIN Kaizen

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33 Leverage fundamental tools to identify opportunities for improvements Facilitate a team meeting using the Faster And Better approach Create a prioritized project pipeline Explain the difference between the 5 different type of Kaizens

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