施耐德精益生产体系流程评估标准.ppt

,G&I / Industrial Deployment,Schneider Production System,SPS Assessment Training (FLV & IC),Icons & meanings, Explanation, Checking point,Good example,Bad example, Question,Introduction: 3 Domains,10 Categories, 38 Lines,1 SPS Notion 1. Work instructions exist for: a. Manufacturing. b. Quality. Standard work has been defined for each station 2. Work instructions for Safety (based on risk analysis) are posted. (instruction board / workstation). Safety instruction could be combined with other work instructions, it must be posted (for critical machines/stations) Observe whether the operator respects the safety instructions 2 SPS Basic 3. Operators were trained using the work instructions Ask the trainers how they fulfill the training tasks Check with the operators 4. Operators understand the work instructions: a. Safety b. Quality c. Manufacturing These 3 kinds of instructions should be posted on the workstations Ask the operators whether they know the different work Instructions do they understand the meanings of the work Instructions,People Commitment - SIM Production 1a - Work Instructions - P1 - Q,3 SPS Standard 5. Work instructions are visual Work instructions are easy to be understood, Avoid long sentence, with favor drawings / chart, colorful pictures Acceptance criterias are clearly defined. 6. Workstation instructions also include maintenance information and change over information (if applicable) Two files are concerned: procedure of variant changing & maintenance check list (with the task and frequency) They should be posted in instruction book in the U-cell 7. Work Instructions are respected (followed) Observe the motion of the operator and check with the instructions 4 SPS Advanced 8. There is a standard process, known by the operator, to follow when a defect is detected (may include signal device, empowerment to stop the line, call the Supervisor) Decision making procedure should be available for operator at cell level Check with operators,People Commitment - SIM Production 1a - Work Instructions - P1 - Q,Focus on: Work Instructions available at workstation / cell / sector Key points: 5 main Work Instructions (in order of priority) Safety (for critical machine/stations) Quality, Process flow chart with Quality check point. Operations / Line Driving Preventive Maintenance / Maintenance (for critical machine/stations) Change Over & Management instructions (versatility chart, 5S) Why we need Work Instructions? To train operators To check the operators on the main rules to follow, especially Safety & Quality To understand the Global Process (Flow-Chart) Work Instructions must be Known & respected Simple and Visual: can be seen at the workstation, avoid long sentences, use favor drawing, easy to understand and acceptance criterias are clearly defined. Keep Updated,Audit in workshop,People Commitment - SIM Production 1a - Work Instructions - P1 - Q,1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS Expert,People Commitment - SIM Production 1a - Work Instructions - P1 - Q,4 SPS Advanced (continued) 9. Operators are routinely participating in determination of new standardized work and definition of work instructions Operators are Involved when re-thinking the system and generating ideas for improvement Ask the operators: Do they have suggestions to improve quality, to reduce the waste? How do they submit the suggestions? is there a formal procedure to follow ?,People Commitment - SIM Production 1b - Short interval production tracking - P3 - Q,1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS Expert,Focus on: Production tracking Key points: Quality & efficiency tracked hourly by operator Pareto analysis for defects and wastes is routinely done and updated (daily, weekly, monthly) “5 why” is used to identify the root cause Recurrence of defects are tracked and analyzed Actions are efficient KPIs: MDR - KE - IE - NEE,Audit in workshop,1 SPS Notion 1. Production Tracking - Good Parts and Defects Numbers - is implemented per shift by the operators Production tracking (include quantity and quality) done by operator per shift Check at cell level 2. Operators are aware of current and potential process and component quality defects related to each product range Operators are aware of quality defects related to each product range Defects are listed by QC (ex. Different code means different defects) Check with operators 2 SPS Basic 3. Production is tracked hourly by the operators (or coherent defined event cycle) Production tracking (include quantity and quality) done by operator hourly If TT0.5H, the interval operator recorded should equal to TT Check the SIM sheet at cell level 4. At the beginning of each shift, there is a review with operators of issues and objectives related to: a) production; b) quality; and c) barriers Observe in the workshop to check: Is there a meeting with operators at the beginning of shift? What kind of topics reviewed in this meeting?,People Commitment - SIM Production 1b - Short interval production tracking - P3 - Q,People Commitment - SIM Production 1b - Short interval production tracking - P3 - Q,People Commitment - SIM Production 1b - Short interval production tracking - P3 - Q,4 SPS Advanced 8. Complex issues are addressed through Six-Sigma or Kaizen Six-Sigma is focus on reducing variability to reach a performance on a process Kaizen is focus on eliminating waste on the whole product flow 9. Pareto analysis of quality issues and waste is routinely done and updated Pareto analysis of quality issues and waste done and updated at least done weekly 10. At least 80% of the difference between red/green is explained down to root causes Use “5 why” to find the root causes,People Commitment - SIM Production 1b - Short interval production tracking - P3 - Q,People Commitment - SIM Production 1c - SIM Production implementation - P4, P10,1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS Expert,Focus on: SIM Production implemented and respected the plant event cycle. Key points: Operators are involved in SIM Production (beginning / end of shift) Objectives Definition Results / Barrier Log & Suggestion system management Safety & 5S Management Support functions are involved in SIM Production Results Analysis / Indicators Review Barrier Log Management Action Plan Management / Escalation system,Audit in workshop Attend the daily SIM meeting,KPIs: Output : Realized - Forecasted Safety + 5S Quality : Service Level - MDR Efficiency : KE/IE NEE/OEE Barrier Log + Action Plan,People Commitment - SIM Production 1c - SIM Production implementation - P4, P10,2 SPS Basic 3. SIM Production is led (required by and participated in) by the Plant Manager Ask plant manager whether he know the plant event cycle, does he/she attend the SIM daily meeting (once per week) Check with production manager 4. Cell / Product Sector short interval cycles and frequency are respected according to SPS There are shiftly, daily, weekly meeting according to SPS Check with operators, line leaders/supervisors, production manager 5. The manager and his team respect the frequency and duration of the event cycle SIM meeting at fixed time with the fixed duration Check with line leaders / supervisors, and observe the daily meeting. 3 SPS Standard 6. Support function s members (Methods , Materials, Logistics , Maintenance , Quality, , Engineering ) participate in SIM Production meetings Observe the daily meeting and check with the participates. 7. Internal KPIs particular to the product or process have been established and are tracked KPIs include output, safety, 5S, OTDM, MDR, KE/IE, NEE/OEE, should be reviewed in the daily SIM meeting Observe the daily meeting to check whether the KPIs be tracked,People Commitment - SIM Production 1c - SIM Production implementation - P4, P10,People Commitment - SIM Production 1c - SIM Production implementation - P4, P10,4 SPS Advanced 8. The shift supervisor manages the action plans and posts them Action plans should be followed and posted on the SIM board. 9. Evidence of dynamic management of the action plans: a) followed up, b) on time, c) evidence of success Check the action follow-up file to see the evidence 10. Human resources facilitate and Assess the SIM Production HR need to be involved in SIM production, Attend the daily meeting frequently, Organize regular audit, 5 SPS Expert 11. Each manufacturing sector consistently reach ones KPIs objectives Check KPIs (output, safety, 5S, OTDM, MDR, KE/IE, NEE/OEE ) report to see the result 12. Internal KPIs show sustained improvement over a 12 months period Check the 12 months trend,People Commitment - SIM Support Functions 2a - SIM support functions - P5, P10,1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS Expert,Focus on: SIM support function implemented and respected the plant event cycle.,Audit in 2-3 support function,KPIs: % Tasks done / Tasks planned % Tasks in time,People Commitment - SIM Support Functions 2a - SIM support functions - P5, P10,1 SPS Notion 1. SIM Support Function concepts (SPS Model) are known Plant management team received the SIM training 2. Plant Event Cycle (frequency, contributors, deliverables) is known by all support functions Plant event cycle are established include frequency, contributors, deliverables. Check with some sector manager and staffs 2 SPS Basic 3. SIM Support Functions is led (required and participated in) by the plant Manager Ask plant manager whether he know the plant event cycle, Are there scheduled 1 to 1 meeting between plant manger and function managers weekly Is there a weekly coordination meeting with all support manager Check with function managers 4. The manager and his team respect the frequency and duration of the event cycle SIM meeting hold at fixed time, with fixed duration Check with support engineers 5. The manager organizes a weekly contact with his staff (1 to 1) There is a weekly 1 to1 meeting between function manager and his staffs to review action plan, workload, priority Check with staffs,People Commitment - SIM Support Functions 2a - SIM support functions - P5, P10,People Commitment - SIM Support Functions 2a - SIM support functions - P5, P10,4 SPS Advanced 9. Diary planning intervals are 2 hours blocks Check several individual diaries to see the interval 10. Tasks planned in the diaries according to the Pareto Analysis of issues/ barriers identified production Tasks & Action plans come from Pareto Analysis of issues/ barriers in production SIM Check staff diaries of support function with the action follow-up file on production SIM board to whether they are matched 11. Human resources facilitate and Assess the SIM Support Functions HR must facilitate and assess the support function SIM, to set up KPIs for all function Dept, to measure staff workload, to organize regular review / audit, 5 SPS Expert 12. Manufacturing KPIs are in continuous improvement Check KPIs report to see the result,People Commitment - SIM Support Functions 2b - SIM Support functions Efficiency - P6,1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS Expert,Focus on: Staff workload management & support function efficiency. Key points: Priorities are known by each staff member - both factory priorities and personal priorities Priorities are taken into account and evidence exists in the “to-do” lists and diaries Resources are adapted: resources are applied to the highest priority activities Activities or actions: does the plant verify and follow-up that the results are sustained ? KPIs: % Tasks done / Tasks planned % Tasks in time,Audit 2-3 support function,People Commitment - SIM Support Functions 2b - SIM Support functions Efficiency - P6,1 SPS Notion 1. Global team workload is assessed. (eg: Annual Human Resource Review or Business Plan Cycle) This global workload assessment is the base of Dept headcount requirement, It should be reviewed once a year or base on business plan cycle. Check with the Dept manager 2 SPS Basic 2. Individual workload is assessed (to do list) Use the some tools to assess the individual workload (e.g. to-do-list). The contents of the file should include workload, priorities, due date, planed ratio Check with dept. manager and staff 3. Support Functions core skills are defined and formalized ( reviewed once a year ) Make the red/green activities self analysis for each non-DVC employee Make a competency (skills & knowledge) assessment for each employee Clearly define the JD for each staff, and the JD should be reviewed once a year. Check with dept. manager and staff,People Commitment - SIM Support Functions 2b - SIM Support functions Efficiency - P6,3 SPS Standard 4. Number of tasks carried out per person per week is scheduled and tracked (Ratio Implemented / Scheduled) Audit several individual do to list and diary. Check the ratio of implemented / scheduled 5. Workload and resources are well balanced according to the objectives Measure and balance the individual workload Resource are applied to the high priority activities according to the objectives 4 SPS Advanced 6. Support functions have defined their own KPIs; they are tracked & analyzed KPIs clearly defined for each department, KPIs should be tracked, analyzed and take actions to improved. Objectives and real data of KPIs should be posted in each department 5 SPS Expert 7. Support Function KPIs are in continuous improvement Check KPIs report to see the result,People Commitment - SIM Support Functions 2c - Suggestion System - P7,1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS Expert,Focus on: Dashboard for Suggestions Key points: Suggestion system is encouraged/managed in SIM production (team leader operators shiftly meeting Suggestion system is formalized : Issue date, accept or refuse Action pilot Implementation date Information is current and updated frequently to match the event cycle of SIM production information is not “old”, forms do not “wait” to filled out. KPIs: Number of suggestions per month Meantime to reply / to implement,1 SPS Notion 1. There is a system or process to record employee suggestions. There is a simple system / process to record suggestions Ask HR manager to do the roughly introduction of the plant suggestion system 2 SPS Basic 2. Project specific suggestion systems are utilized to formalize employee feedback There is a formal procedure to define how the suggestion system works Suggestions could be developed as action plans, projects 3. Suggestions are visual and a feedback is given within 30 days Suggestion sheets are posted on the board to show the situations and progress. Check the issue date and feedback date to see whether the duration is 30 days 3 SPS Standard 4. Supervisors work with employees to refine suggestions Supervisor collect, refine and distribute the suggestions once a day 5. A committee evaluates suggestions Every day, at a fixed time, the designated contact person in each department examines the new suggestions and allocates them to his department (one coordinator designated per sheet).,People Commitment - SIM Support Functions 2c - Suggestion System - P7,3 SPS Standard (continued ) 6. Suggestions are visual and a feedback is given within 2 weeks The coordinator must face to face discuss each new sheet with the requester to well understand the problem, the proposal, and so on. If the suggestion is accepted, the coordinator and the requester will decide on the appropriate action to be undertaken Once an action is undertaken, the coordinator and the requester should confirm it by signing on the sheet Check with point 3 4 SPS Advanced 7. Suggestions are visual and a feedback is given within 1 week Check with point 3 8. The content of the suggestions becomes more important than the qty posted : KPIs tracked Improve the suggestions from quantity to quality. KPIs tracked with the targets, include number of suggestion issued, waiting time for feedback, action undertaken rate, action on time implemented rate 9. There is a incentive system in place for suggestions Reward system for suggestions is existed in the plant Check with the operators and staff whether they know this reward system,People Commitment - SIM Support Functions 2c - Suggestion System - P7,5 SPS Expert 10. Additional rewards exist for “outstanding “suggestions Clear definition of the outstanding suggestion is existed The result of the suggestion should be measurable. (ex. low cost, high savings) Check with the operators and staff whether they know this additional rewards 11. KPIs show continuous improvement of suggestion system Check KPIs report to see the result,People Commitment - SIM Support Functions 2c - Suggestion System - P7,People Commitment - Continuous Improvement 3a - Operator flexibility - P2,1 - SPS Notion 2- SPS Basic 3- SPS Standard 4 - SPS Advanced 5 - SPS Expert,Focus on: Matching demand and resources. Key points: Number of operators in a cell varies according to workload demand Same level of KE with minimum and maximum of operators (KE 80%) Production clearly understands their demand - including distribution center shortages and / or customer expedites and adjusts their schedule and staffing to respond KPIs: Operator Efficiency KE SUR (auto),Audit in workshop,1 SPS Notion 1. Concept of operator flexibility and team work spirit accepted Observe in the workshop to see whether the operators move inside the U-cell 2 SPS Basic 2. Operators are trained to operate several stations / machines within a line / cell Observe whether the operator moves to upstream and downstream based on flow rate inside the U-cell Check whether the operators are trained with the detail information in multi-skill chart 3. Flexibility and/or multi machine manning is partial