Lean Operations                                                                               Excellence                  ...
Performance improvement in reality Lean Operations                                                           Excellence   ...
Standardization versus improvementLean Operations                                                         Excellence      ...
Performance improvement on                                        Lean Operations                                         ...
Standardization                                                  Lean Operations                                          ...
Standard work by position                                                                                                 ...
Lean Operations                  Kamishibai                                Excellence                  Manager Standard Wo...
Problem solving, kaizen and                                                Lean Operations                                ...
Lean Operations                   Types of kaizen for SME                  Excellence                   Quick and easy kai...
Lean Operations                                                                 Excellence                                ...
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Roel Berkhout - Philips Industry Consulting

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Roel Berkhout - Philips Industry Consulting

  1. 1. Lean Operations Excellence De Motor van Lean Philips Industry Consulting Eindhoven Roel Berkhout, May 2012 1 Industry Consulting 24 mei 2012, Roel Berkhout Maintain the best way of working Lean Operations Excellence 2 Industry Consulting 24 mei 2012, Roel Berkhout Philips Industry Consulting Mei 2012, Page 1
  2. 2. Performance improvement in reality Lean Operations Excellence gap! Performance Time 3 Industry Consulting 24 mei 2012, Roel Berkhout Lean Operations Problems improve the work place Excellence and the work itself “ No one has more trouble that the person who claims to have no trouble.” - Taiichi Ohno 4 Industry Consulting 24 mei 2012, Roel Berkhout Philips Industry Consulting Mei 2012, Page 2
  3. 3. Standardization versus improvementLean Operations Excellence Stabilize Stabilize Standardise Standardize Continuous Improvement Improve Improve Challenge Challenge 5 Industry Consulting 24 mei 2012, Roel Berkhout Lean Operations Standardization perspective Excellence Actual (Performance) Performance Kaizen Standard Problem Kaizen (Capability) Problem Time Standard: Problem: Kaizen: Record of best Actual Develop a better known method performance has method to perform to perform work fallen below work repeatedly repeatedly proven capability 6 Industry Consulting 24 mei 2012, Roel Berkhout Philips Industry Consulting Mei 2012, Page 3
  4. 4. Performance improvement on Lean Operations Excellence the shop floor …. Do you have a No Create and Implement good standard? a good standard Yes Make adherence to Are standards No being followed? Follow the standard standard visible Yes Are there big No deviations from Kaizen the standard? Yes Yes No Problem Solve Is data available? Collect /improve Data 7 Industry Consulting 24 mei 2012, Roel Berkhout A3 problem solving method Lean Operations Excellence 1. Clarify the Problem 2. Break Down the Problem A3, similar 3. Target Setting To 8D 4. Root Cause Analysis 5. Develop Countermeasures 6. Implement Countermeasures 7. Monitor Both Results and Processes 8. Standardize Successful Processes, learn from failures 8 Industry Consulting 24 mei 2012, Roel Berkhout Philips Industry Consulting Mei 2012, Page 4
  5. 5. Standardization Lean Operations Excellence Standard Work Standard Procedures focused on focused on solving NORMAL ABNORMALITIES 9 Industry Consulting 24 mei 2012, Roel Berkhout Standard work Lean Operations Excellence The written current best method for safe and efficient work that meets the regular quality and provides the standards for improvement Four Elements: 1. Work elements & sequence the order in which the work elements are done in a process 2. Total standard time & standard time per work element 3. Input materials, tools and information required 4. (Standard Work-in-Process) minimum number of unfinished jobs necessary for a smooth completion of a work sequence 10 Industry Consulting 24 mei 2012, Roel Berkhout Philips Industry Consulting Mei 2012, Page 5
  6. 6. Standard work by position Lean Operations Excellence Standard work is LESS structured Executive • % of time standard • Specific sequence • Specific time of day • More time for discretionary tasks Supervisor and Supporting Roles (Engineering, Maintenance, Sales, Finance, Continuous Standard work is MORE structured Improvement, Purchasing) • % of time standard • Specific sequence Team Leader • Specific time of day • Less time for discretionary Operator SHOP FLOOR 11 Industry Consulting 24 mei 2012, Roel Berkhout Standard Work Lean Operations Excellence Document No.: xxxx STANDARD OPERATION Washington F IS - F -P S- 2 41 / EN P la nt: ver s io n 0 1 Revision Level: 4 Part Work- Page Number xxx Part Name Bolster Line : EQ Bolster station: Woodstock No: 1/1 Tim e: No. Operation = SAFETY = QUALITY = TIP 30 Sec Sketches / Photos / etc. Remove cavities 3 & 4 from the mould tool. 4 1 Remove parts from tool Place parts onto left side of bench (Fig1) S piking Remove the spiking Remove the waste then place the frame onto the bench Ca vitie 2 frame from the upper Ensure frame handle is pointing away from you and spikes are pointing upwards. 1 4 Cavitie s 1 3 2 2 tool Fig 1. 3 Fold waste and place Fold the waste from the frame and place it onto the granulator cooling stand, using it to 3 onto to stand. push the existing waste into the granulator (fig 2). Gra n u la to r Remove the spiked Remove the spiked frame from underneath the bench place it into the guides on the Co o ling s ta nd upper mould tool (fig 1) 4 frame from the underneath bench Ensure that the handle is pointing towards you is fully located against the censor Fig 2. Wh ite 5 - Take one white & green LH clip from the dispenser. Place one white & green - Place the green clip into the center clip position and the white into the bottom location 5 clip into cavities 3&4 on cavity 4. - Take one white & green RH clip from the dispencer. - Place the green clip into the center cl Gre e n Wh ite Fig 3. Issued S ig na tur e Checked S ig na ture Approved S ig na t ur e SKILLED S ig na t ur e Non Conforming Product: Name: Name: Name: OPERAT OR P la c e reje c ts in re je c t c o nta ine r. Re c o rd o n P ro c e s s M o nito r Function: Function: Function: Name: She e t. If 3 o r m o re re je c ts fo und with s a m e fa ult ca ll Ga p Le a de r. 12 Industry Consulting 24 mei 2012, Roel Berkhout Philips Industry Consulting Mei 2012, Page 6
  7. 7. Lean Operations Kamishibai Excellence Manager Standard Work • Select card • Follow instructions on card • Turn green side if OK / turn red side out if not 13 Industry Consulting 24 mei 2012, Roel Berkhout Lean Operations Excellence 14 Industry Consulting 24 mei 2012, Roel Berkhout Philips Industry Consulting Mei 2012, Page 7
  8. 8. Problem solving, kaizen and Lean Operations Excellence standardization standards …. to describe how to keep the best normal operating conditions Performance kaizen problem solving …. to develop a better …. to bring the performance back method to perform the to the level of proven work repeatedly performance Time 15 Industry Consulting 24 mei 2012, Roel Berkhout Lean Operations Standardization perspective Excellence Actual (Performance) Performance Kaizen Standard Problem Kaizen (Capability) Problem Time Standard: Problem: Kaizen: Record of best Actual Develop a better known method performance has method to perform to perform work fallen below work repeatedly repeatedly proven capability 16 Industry Consulting 24 mei 2012, Roel Berkhout Philips Industry Consulting Mei 2012, Page 8
  9. 9. Lean Operations Types of kaizen for SME Excellence Quick and easy kaizen Team Member = Short Kaizen or OPL Kaizen Event / Blitz Line team + support Structured guided learning event Full-time ca. 1 week 17 Industry Consulting 24 mei 2012, Roel Berkhout Lean Operations Excellence Benefits of mobilizing the organization Circle of Concern Circle of Influence 18 Industry Consulting 24 mei 2012, Roel Berkhout 1 Philips Industry Consulting Mei 2012, Page 9
  10. 10. Lean Operations Excellence Roel Berkhout Roel.Berkhout@Philips.com +31610924113 19 Industry Consulting 24 mei 2012, Roel Berkhout Philips Industry Consulting Mei 2012, Page 10

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