0.Productivity Improvement_2007E.ppt

1、Productivity Improvement Project Review,SBG/SBU: HTT/GTSS Revision: E Last updated:11/08/2007,What Is the Problem and Our Target?,Project Background Design department reorganization Group FPY=96.6% Drawing finished in CV team is less than FE team Project Scope Design work process within CV design gr

2、oup Headcount limited by existing organization (10 HC) and hiring plan,Problem Statement Current group productivity is 69.3% which is not enough to meet increasing business needs Project Objective Increase group productivity by 20%, (from 69.3% to 90.0%, variation = 97%),Team Chart Leader: Lucy Xia

3、(Design Engineer) Member: Charles Li (Design Engineer) Eric Li (Design Engineer) Coach: Amy Zheng (Lean Expert Candidate) Sponsor: Peter Zhang (CV Design Manager),Project Milestone Define05/25/2007 Measure07/13/2007 Analyze08/17/2007 Improve09/21/2007 Control 10/26/2007,Our Project: Productivity Imp

4、rovement of CV Design Group,How do We define “Productivity”,Productivity Definition,Output Hours Design Hours Productivity= X X100% Design Hours Time in office,= Efficiency X Time Utility,Business Impact,Identify project saving from Productivity Improvement Increase group productivity by 20%. Qualit

5、y Performance FPY=97%. Business Impact in USD Expense for every designer is $20/hour, 20% design productivity improvement within 10 head counts group means $118,080 saving/year. Potential impact on reducing cycle time,$118,080 Saving from Productivity Improvement per year,Thought Process MAP,T-MAP:

6、Our Visual Project Road Map,Q1- Who is our customer? (SIPOC, Management team is our main customer) Q2- What are customers expectations? (SIPOC, High productivity of high quality delivery) Q3- What is our current productivity level? (69.3% +/-8.49%) Q4- How will we know if we are successful? (SSP cha

7、rt, Productivity increase by 20%, from 69.3% to 90%) Q5- How much benefit will our project bring? (SSP chart: $118,080 saving/year) Q1- What is our current work process? (As is Process map, UDO) Q2- What are the factors that affect productivity? (Brain storming, Fish Bone) Q3- What measurements do w

8、e need? (Productivity record, FPY record, OCCT record, Daily Work record) Q4- How to ensure the accuracy of data collected? (MSE, DWR database, Timesheet) Q1- Which factors most effect productivity? (C GM/Ford Requirement: High Productivity High Quality On time delivery,1,2,2,3,4,5,6,7,8,Process Map

9、 High Level,Vision of Current Working Flow,Process Map Detailed,Current Working Process: Identify Value-Added Step,Value Added Step: Design Work,Fish Bone,Identify All Facts that May Effect Productivity,CV DWR Data Analysis,31% DWR of CV Design Group was LAYOUT,Layout Type Study,Improvement Opportun

10、ity,C&E Matrix,Top 5 Causes of Productivity Voted by Team,No1.New drawing, new project No2.New Hire No3.Lack of related training No4.No Standard Process No5.Lack of communication,Replace with New Update C&E(Amy),Top 5 Causes,Hunter C&E Matrix,Identify Which Causes Bring Most Benefit with Least Effor

11、t,C&E Analysis,Identify Sweet Spot to Improve,Improvement Opportunities A 新员工/ New hire B 新图, 新项目/ New drawing, new project D 没有得到相关的培训/ Lack of related training C 客户没有经验/ Requestor inexperience E 没有标准/ Lack of standard F 缺少交流/Lack of communication,Less Effort,More important,C&E Analysis,Find a curv

12、e to estimate our results,How can we know only 6 sweet spot will let us achieve our target?,Experience curve for Productivity,Our baseline 69.3%,Our Target 90%,100%,Causes,Productivity,New hire,New drawing,Lack of training,Requestor inexperience,Improvement Opportunities Estimate benefits for produc

13、tivity improvement A New hire 5% B New drawing, new project 5% D Lack of related training 4% C Requestor inexperience 2% E Lack of standard 2% F Lack of communication 2%,Lack of standard,Lack of communication,Improvement Action,To Achieve Higher Productivity,New hire New drawing/project Lack of rela

14、ted training Requestor inexperience Lack of Standard for Layout work Lack of communication,Root Causes,Improve Actions,Training plan Design skill matrix Knowledge Share DWR Input Quality Track Lean Project Email Template (Standard format) English Communication,Control Chart for Productivity,Group Pr

15、oductivity is improved!,P-value0.05Conclusion: Our productivity data is a normal distribution.,P-Value0.05 Conclusion: Productivitywas improved significantly.,Other CTC for reference,Continuously improvement,Average time utility in our group is 76%, In next step we want to take some actions to impro

16、ve it to 80%.,99% Our FPY,We sustain our design Quality!,FMEA,Failure Mode 1. Its hard for planner to find the most suitable designer for the task. 2. Lack of effective communication with requestor 3. Wrong Input information. 4. Checker and Designer is inexperienced,Potential Failure Mode Existed!,C

17、ontrol Plan,Maintain our success Monitor our result Review the data monthly Report the data after 3 months.,Next Step,Appendix,World Wide Training Plan,Design Skill Matrix,Innovation Skill Matrix,Visual management.,Expert list,Quick Problem Solving.,Objective: Makes People better Everyone is trainer

18、 Reduce knowledge waste Knowledge champion of the year Improve presentation skills,Knowledge Share,Why giving up hard-won knowledge!,Improvement Action,Track Input Quality!,Improvement Action,Improve Our Communication Skill.,Finished drawing number in different team,CV vs PV vs FE team! Per HC,Group Average Drawing number per week CV 2 PV 2 FE team! 4,There