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A Beginners Guide to Production Management

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This course gives an introduction to Production Function, Roles and Responsibilties, Shop floor management, Lean Manufacturing, 5S, MIS report formats and templates. Would serve as a ready reckoner …

This course gives an introduction to Production Function, Roles and Responsibilties, Shop floor management, Lean Manufacturing, 5S, MIS report formats and templates. Would serve as a ready reckoner for professionals in the industry. Please visit www.businessense.in for downloading this presentation & more details.

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  • 1. PRODUCTIONMODULEAn initiative of Hash Management Services LLPA Business Sense PublicationFor more free resources visit www.businessense.in
  • 2. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Overview ‘The Essentials’ series from Business Sense is an initiative to empower the professionals and students in performing moreefficiently and effectively in the organization This publication is aimed at bridging the gap between the institutions and the industry by providing the fundamentals ofmanufacturing management which are not offered by any of our institutions/curriculum This course would immensely benefit professionals and students who are joining manufacturing organizations At Business Sense, we help medium scale manufacturing units improve their operational efficiency through consultingengagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED,Kaizen and other tools We promise to double the productivity in less than 33 days of our effort In addition, our web application would help the senior management in monitoring the important business updates every dayand provide them analytics and enable them better decision making. Useful if your organization do not have an ERP For more details, please visit www.businessense.in You can subscribe to our bi-weekly newsletter here. Follow us:
  • 3. Contents Section 1 – Introduction and Basic Processes Section 2 – Shop Floor Management Section 3 – MIS Reports and Analyses Points Section 4 – TemplatesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 4. Production Function- Introduction Production is one of the most critical function inany manufacturing organization. This functionrepresents the set of activities through whichthe product is made and delivered according tothe client’s requirements. Production function normally encompassesvarious departments/shops based on the typeof products and the operations involved (e.g.press shop, machining, polishing, plating,assembly etc).Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 5. Production Function- Introduction The components move from each shop/machine to the other, once the requiredoperations are completed. (Sometimes the product would be stationary and all theoperations would be carried out on the product. E.g. Ship building). At each stage the component is added value (value addition) and transforms to a finishedproduct.Value Addition at each stageProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 6. Organization Structure*Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.CEOProductionManagerProductionSupervisorProductionSupervisorProductionSupervisor This is a standard organization structure for ProductionFunction Purchase Manager reports to the CEO of the company In a large organization, Production Manager mightreport to Factory Manager / Manufacturing Head There can be a few Production Supervisors ( for differentlines / processes / shop floor) reporting to the ProductionManager Each Production Supervisor would typically focus on asingle / specific processes or line *- A typical functional hierarchy is mentioned here. It mayvary according to each organization.
  • 7. Responsibilities of Production Manager Delivery - Overall responsibility of delivering finishedgoods as per the customer’s requirements – Ensuring100% on-time delivery Quality - Meeting the Quality requirements set by thecustomer and taking steps to exceed them Productivity - Optimum usage of the resources(men/materials/machine) Cost – Minimizing cost ( reducing reuse/defects ,process modifications/improvements ) Safety & Morale – Ensuring Safety of personnel andimproving Morale of the employeesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 8. Responsibilities of Production Supervisors Production planning – Allocation of resources(Men/Machine/Materials) properly so as toensure smooth production flow and delivery Productivity – Ensuring a smooth productionflow / dynamically monitoring the productionprocess and make necessary changes basedon the requirements Quality – Measuring and analyzing thecurrent quality levels and taking necessarysteps to improve and achieve the qualitylevels set by the managementProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 9. Responsibilities of Production Supervisors Cost – Taking necessary steps to reduce costs– reducing defects / improving processes Delivery – Ensuring 100% on-time delivery.Analysis of delays in deliveries andimprovement from the current situations Safety & Morale – Achieve 0% Accidents andIncidents(Near-miss). Improving Morale ofthe personnelProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 10. Production Process -1 Production Plan created by the Production Planning department /production manager is sent to the production supervisors Production supervisors plan for the day’s production based on theweekly / monthly production planProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 11. Production Process - 2 Order-wise requirements of allmaterials (calculated from the Bill ofMaterials (BOM)) would be obtainedfrom the stores using Materials IssueRequisition (MIR) slip Once the materials are obtained theyare sent to the respectiveprocess/machines for completion.The Supervisor also creates a job cardfor each lot/item which travels alongwith the product throughout theentire processes.Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 12. Production Process - 3 Quality is measured at each stage so as toreduce reworks and rejections ( however, asper lean manufacturing methodology,inspection is a non-value added activity andhas to be eliminated. It might take a long timefor a SME to reach this goal) At the end of the production process,necessary quality checks are made and theproducts are packed and delivered to thecustomers.Please note this is only the basic process. There may be delays /stoppages in production due to quality issues, non-availability ofmaterials, absenteeism etc.Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 13. Contents Section 1 – Introduction and Basic Processes Section 2 – Shop Floor Management Section 3 – MIS Reports and Analyses Points Section 4 – TemplatesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 14. Daily Production Plan Monthly Production plan is broken down into Weekly and Daily production plan for each shop/operationby the Production manager and sent to the respective Production Supervisors Production Supervisor should plan for one day’s production in advance. i.e. tomorrow’s production planshould be planned today by the individual supervisors (before office closing hours)MonthlyProduction Plan------------------------------------------------------------WeeklyProduction Plan------------------------------------------------------Daily ProductionPlan----------------------------------------------------------------------------------------------------Daily ProductionPlan----------------------------------------------------------------------------------------------------Daily ProductionPlan----------------------------------------------------------------------------------------------------WeeklyProduction Plan------------------------------------------------------WeeklyProduction Plan------------------------------------------------------Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Daily ProductionPlan----------------------------------------------------------------------------------------------------
  • 15. Daily Production Plan Once the Production supervisors obtainthe daily production plan, they should plan& allocate the resources ( men, machineand materials) for the next day’sproduction Resources and work allocation should becarried out in the previous day eveningAllocation of ResourcesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 16. Daily Production Plan Once the employees enter the shop floor,they should be able to pick up thematerials and start working. ( If theproduction plan happens in the morning,the company loses around 20 minutesbefore employees are allocated some joband start working)Work Should startimmediately ( at thestart of the shift)Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 17. Daily Production Plan Supervisor allocates the job to the right personnel and follows it so that the productiontarget for the day is achieved. In case of any changes in the plan, he/she consults with the Production managerimmediately and make necessary changes in the shop floor He/she informs the employees and arranges materials accordingly At the end of the day, Production status is reported to the Production Manager and the planfor the next day is doneProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 18. Shop Floor Management Lean Manufacturing Tools 5SBoth these tools are useful in eliminating non-value added activities and organizing theshop floor in a visually appealing mannerProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 19. Lean ManufacturingDefinition:A systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the productor service at the pull of the customer.Doing more and more with less and less…Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 20. Lean ManufacturingValue Adding Process:A process step thattransforms or shapes aproduct or service which iseventually sold to acustomer.Non-Value AddingProcess (Waste):Process steps that taketime, resources, or space,but do not add value to theproduct or service.Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 21. Lean TerminologyValue Stream: All activities, both value-adding and non-value-adding, currently required to bring a productor service from concept and/or raw materials into the hands of the customer.Value Stream Mapping: Investigating the current and possible future state of the system or process. (Total time vs..total value-added time from beginning to end) Typically value-added time is five percent of the total time.Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 22. Value Stream Mapping – VSM takes a holistic view of the operations; suppliers, internaloperations and the customers. This gives a clear view of the processes and thecritical areas where various improvements can be initiated.22Focus AreasProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 23. Benefits of Value stream Mapping Visualize and expose, “If you can’t see something how can you improve it” Identifies waste and its sources Opens up communication with the team members Creates a blue print for the futureProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 24. Waiting Transportation Over Processing Inventory Motion Defects Over ProductionThe Seven WastesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 25. Characteristics Person waiting for a machine People watching machines run Machine or materials waiting for a person Lack of concern for equipment breakdowns or downtime Long setup times Unbalanced operations Inconsistent work methodsDefinition Idle time in which no valueadded activities take place Person wait time Machine wait time Material wait timeExamples Line Balance Buffers Idle Builders1. WaitingProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 26. 2. TransportationCharacteristics Multiple storage locations Multiple movement of material Extra carts, fork lifts, dollies, material racks Damaged materials Poor facility layout Return of materials not used in production Large lot processing and in process buffersDefinition Any unnecessary materialmovement that does notsupport the leanmanufacturing systemExamples Conveyors Forklifts Transfer Carts Movement betweenplans Functional vs.. processlayouts Distribution channelswith many levelsProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 27. 3. OverprocessingCharacteristics Process bottlenecks Lack of clear customer expectations Lack of customer input concerning requirements Redundant approvals Extra copies and excessive information Inefficient policies and proceduresDefinition Effort which adds no valueto a product or service Work that can becombined with otherprocesses Enhancements that aretransparent to thecustomerExamples Multiple Tests Parts Handling InspectionsProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 28. 4. InventoryCharacteristics Extra space on receiving docks Build up of material between processes Not using FIFO (first-in-first-out) Extensive rework when problems surface Additional material handling Long lead times for engineering change Interest charges and opportunity costsDefinition Any unnecessary suppliesor materials that do notsupport the ‘Just In TimeProduction System’Examples Material on site (WIP) Strategic Buys Long Supply ChannelsProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 29. 5. MotionCharacteristics Looking for tools and parts Excessive reaching or bending Material too far apart (walk time) Extra equipment for moving parts Picking up things only to set them back down Large batch sizes Poor plant layoutDefinition Any movement of peoplewhich does not add valueto the productExamples Product/work design Product presentation Transportation to line Access to materialsProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 30. 6. DefectsCharacteristics Extra floor space, tools and equipment Extra manpower to inspect, rework and repair Additional inventory Questionable quality Lower profits due to scrap Incapable processes with excessive variation Inadequate tools or equipmentDefinition Repair of a product orservice to fulfill customerrequirementsExamples Warranty Yield Rework ScrapProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 31. 7. Over ProductionCharacteristics Inventory stockpiles Extra or oversized equipment Unbalanced material flow and confusion about priority Extra parts storage racks and manpower Build ahead of demand Large lot sizes or batch processingDefinition Producing more thanneeded ‘Work ahead’ Producing at a faster pacethen neededExamples Stock Over build of capacity Unbalanced production Lines backing upProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 32. Establishing Single Piece FlowBatch Processing:High Work-In-Progress items (WIP)Quality Problems could be identifiedonly at the end of the processesSingle Piece Flow Processing:Less Work-In-Progress itemsQuality Problems could be identifiedinstantly and can be correctedProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 33. Contents Section 1 – Introduction and Basic Processes Section 2 – Shop Floor Management Section 3 – MIS Reports and Analyses Points Section 4 – TemplatesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 34. (Seiri) – Sort Distinguish between what is necessary and unnecessaryitems. Remove the latterSeiton – Set in Order /StraightenEnforce a place for everything and everything in itsplace.Seiso – Shine Clean up the workplace and look for ways to keep itclean.Seiketsu - Standardize Maintain and monitor adherence to the first three Ss.Shitsuke – Sustain Follow the rules to keep the workplace 5S-right. “Holdthe gain.“WHAT IS 5S ?5S – a series of 5 words in Japanese language aimed at workplace organizationProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 35.  Five steps to the culture of keeping thework place clean, organized, systematic andsafe A foundation for all improvements and leanjourney Every employee is engaged andempowered. Reveal the wastes and their causes in theprocess not seen by observation. To put it simply “Work Place Organization”WHAT IS 5S ?Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 36.  Determine red tagging criteria for all non-moving items Designate red tag holding area in thestores separately Identify person responsible for holdingarea Obtain red tags Talk to area workers Perform red tagging and record taggeditems in log book Move tagged items to holding area1. Sort out – How to do it?Red TagItem Name:____________Item Code :____________Quantity Available :____________Reason for nil usage :____________Future Rack No :____________Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 37. WastepaperSpecialRecycle / disposalScrap ironSeparate unnecessary from the necessary ones,collect category-wise for easy disposalSeparate while sorting outProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 38. Unnecessary ItemsBefore disposing, take care to check with Finance departmentSort - Analyze the Unnecessary ItemsUnnecessary ItemsNo Value. Easy toDisposeRetains Some ValueNo Value. But Costlyto disposeDispose offImmediatelyLook out for saleAnalyze disposalmethodsOnly the NecessaryItemsNext ‘S’Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 39. After Sorting out the unnecessary items, the needed items have to be classified by useand arranged so as to: Minimize search time and effort Facilitate easy return and retrieval Place each item in a designated addressIn simple terms,“A place for everything and everything in its place”.2. Set in OrderProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 40. Set in Order - ImplementationNecessary ItemsFrequently Used /Fast MovingModerately Used /Slow MovingRarely UsedPlace near Point ofUsePlace it distantlyKeep Separately withlabelsProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 41. Set in Order – After Mapping MotionWorkstation 100 Workstation 200 PartsBeforeAfterWorkstation 100 Workstation 200PartsProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 42. Tools on revolving trolley Tool Board at machine Tool rackAt the workstations – Point of use – Reduce Wasteful MotionThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the picturesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 43. Supply of the necessary things at the correct placeWhat? How much? Where? For what ?Utility spacesTools Measuring instrumentTool TrollyPut in order, ready when you need themProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 44. Easy to search, pick and placeSet in Order – in officeThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the picturesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 45. 3. ShineCleaning the work place including machines,tools, floor, walls and other areas.On cleaning, a lot of abnormalities like cracks,loose nuts, bolts, oil leakage, loose wires, etc.can be detected and rectifiedCleaning is inspection and is a kind of healthcheck for the shop floor.Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 46. How to Start? Initially, a company-wide participation (including all categories ofemployees) for at least “one hour”. Collective cleaning makes the joblighter Maintain the record of abnormality observed and their removal Continue this process till a basic level of Cleanliness is reached. Sustain by: 5-Minute Shining every shift Develop a Cleaning Calendar and maintainProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 47. Necessary ItemsUnnecessary Items Sort/DiscardPlannedMaintenanceDefect orIrregularityFoundClean/InspectInstant MaintenanceArrange/OrderShine - ImplementationProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 48. Each employee cleans his job area and/or machines or plants themselves.The advantage: Defects are promptly discovered.Cleaning is checkingClean workplace, equipment and prevent defectsProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 49. Collective Cleaning – Shining Workplace …These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the picturesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 50. DailyWeeklyMonthlyColor-Coded Stickers facilitate• Lubrication• Checking for abnormalitiesQuarterlyCleaning Calendar for a Machine - ExampleThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the picturesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 51.  Standardization here refers to the system required to practice Sort, Set In Orderand Shine regularly and in a well planned manner (to assure continuity of theprocess) Following will help in putting such systems: Conduct 5-S Audit Visually display on shop floor: Trend charts of 5-S performance Latest Audit Form Improvement projects and their status4. StandardizeProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 52.  Each area would have a person responsible for it. Area Owners named in 5 S Map are responsible for: Completing the restoration/ improvement projects (Improvementprojects originate from abnormalities identified in audit) Find root cause and take preventive projects to avoid such abnormalities Some standard preventive projects: Make all storage areas transparent. Develop system to trace the movement of reusable tools etc. Make the locations visual for all items. Kaizens (Continuous Improvement) to eliminate the source of dirt, dust,contamination, etc.StandardizeProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 53. Standardization and Visual ManagementTokens placed to indicatethat mould has been takenfor production.These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the picturesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 54. StandardizeSystemise and standardize 3 Ss involving employees and use their experiencesMondayTuesdayWednesdayThursdayFridayActivitiesInstructionsColor standardCleaning plan-Work instructions- procedure guidelines- Markings- inscriptionsOrdner 1Ordner 2Ordner 3Ordner 4Ordner 51 2 34 5 67 8 9# 0 >32°GF 100 MAXMIN- Monitors- IndicatorsProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 55. 5. Sustain and Self Discipline The first 3 Ss are easy to start, 4th and 5th focus on sustaining the effort. The greatest benefit of the 5S is that it helps people to focus andacquire self discipline. A self disciplined employee always shows positive interest andovercomes resistance to change. People’s behavior is a reflection of the environment. So it is our responsibility to first create a clean, pleasant and a safeworking environment It should become a: a culture a part of daily workProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 56. Self Discipline – How to bring in? Publicize Systems for doing 5 Ss, Rules for Audits and evaluations. Conduct Regular 5-S Patrol, Audit Conduct Periodical 5-S Contest Actively Promote 5-S Make doing 3S - a matter to be proud of. Train to Standardize & Discipline a habit.Continuous FocusProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 57. Standardization and Self-DisciplineNote: The token of the employee in the place of tool taken by him.These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the picturesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 58. Transparent containers litresmarked;Level reordedDrip catcherStandardize : Make the contents visible– Color codeThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the picturesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 59. Contents Section 1 – Introduction and Basic Processes Section 2 – Shop Floor Management Section 3 – MIS Reports and Analyses Points Section 4 – TemplatesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 60. Section 3 : MIS Reports & Analyses The list below explains the various parameters to track, the reports to generate, thefrequency and the person-in-charge in the Production function:Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Report Name Key Parameters Nature of Report Frequency Prepared byMonthly Production report Monthly Production - Plan Vs Actual Product-wise / for allworking days - chartMonthly Production ManagerMonthly Rejection / Rework report Monthly Rejection / Rework status - TargetVs AchievedProduct-wise / Defectcategory-wise - paretoanalysisMonthly Production ManagerDaily Production Report Tracking the daily production - Plan VsActualProduct-wise Daily ProductionSupervisorDelivery performance Report Plan Vs Actual Delivery Status - product-wise / customer-wiseProduct-wise / customer-wise Monthly Production ManagerAccident / Near-Miss report No of Accidents / Near-miss happens in themonth - area-wiseExplain the accident,corrective and Preventiveaction takenMonthly Production Manager5S Audit Report Consolidation of the scores of the variousareas in the shopfloorScores of the various teamsand the improvements overthe last auditsMonthly Production Manager
  • 61. Analysis/questions to ask from the reports…Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Report Name Nature of Report Key Parameters Questions to AskMonthly Production report Product-wise / for allworking days - chartMonthly Production -Plan Vs ActualWhat is the achievement against the plan? For each product / product categories ? Is there atrend that week-end production is higher than other days? Last weeks production is higherthan other weeks production? Why ?How to avoid this in the future?Monthly Rejection / ReworkreportProduct-wise / Defectcategory-wise - paretoanalysisMonthly Rejection /Rework status - TargetVs AchievedWhat is the rejection rate / rework rate? Is this monitored frequently? What is the pareto ofdefects? How long the major defect is figuring in the list? When it will be resolved? How?Daily Production Report Product-wise Tracking the dailyproduction - Plan VsActualAchievement of days production vs. planned target. Is there any bottlenecks in achieving thetarget? If any product does not meet the plan, move it to the next days plan? Any qualityissues faced? How the issue is solved? What is the corrective and preventive solution?Delivery performanceReportProduct-wise / customer-wisePlan Vs Actual DeliveryStatus - product-wise /customer-wiseWhat is the delivery performance against the customer orders ? How many orders aredelivered On-Time-In-Full (OTIF).( OTIF means, all the customers orders have been sent ontime and the full quantity ordered )Accident / Near-MissreportExplain the accident,corrective andPreventive action takenNo of Accidents / Near-miss happens in themonth - area-wiseHow many accidents occurred in the month ? How many near-miss happens in month? Arethey being recorded? How to eliminate the accidents in the future? Corrective andPreventive Action?5S Audit Report Scores of the variousteams and theimprovements over thelast auditsConsolidation of thescores of the variousareas in the shopfloorAre the shop floors looking tidy and clean? Is it visibly managed ? Is the area free of dust?Are the machines cleaned daily?
  • 62. Role of the Senior Management All the above initiatives would work only if the senior management iscommitted to the change and continuously monitors the processes. There would be a lot of resistance initially for this and would take 2-3months for the initiatives to sustain. Regular interactions with the personnel are the key and a systematicfollow-up is vital for the initiatives to be successful. Meetings with the respective personnel can be scheduled for a pre-determined date every month/week. The minutes of the meetings (MOM) should be sent to the respectivepersonnel for further action. MOM should be precise with the action plan,responsibility and the target date for completion.Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 63. Contents Section 1 – Introduction and Basic Processes Section 2 – Shop Floor Management Section 3 – MIS Reports and Analyses Points Section 4 – TemplatesProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 64. Monthly Production ReportS.No DateProduct A Product B Product C TotalPlan Actual Difference Plan Actual Difference Plan Actual Difference Plan Actual Difference1 1-Feb 100 90 10 200 180 20 200 175 25 500 445 552 2-Feb 125 120 5 150 135 15 150 125 25 425 380 453 3-Feb 150 140 10 200 190 10 175 150 25 525 480 454 4-Feb 200 175 25 175 175 0 150 130 20 525 480 455 5-Feb 175 175 0 150 130 20 165 140 25 490 445 456 6-Feb7 7-Feb8 8-FebAssuming that the company produces three products…Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
  • 65. Monthly Rejection/Rework ReportThis is for one product. Similar reports for other products to be created…Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Product A Quality Issue 1 Quality Issue 2 Quality Issue 3 Quality Issue 4DateProductionPlan Actual Production Rejection Rework Rejection Rework Rejection Rework Rejection Rework1-Feb2-Feb3-Feb4-Feb5-Feb6-Feb7-Feb8-Feb9-Feb
  • 66. Daily Production ReportProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Company NameDate:Product Category Previous Rework Plan ActualProduct A 15 165 135Product B 5 200 170Product C 10 175 160Total Output 540 465Cumulative Output till datefor the monthQuality Issues: Rework RejectionX 5 2Y 8 4Z 10 3
  • 67. Delivery Performance ReportProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Delivery PerformanceS.NoCustomerOrder No ProductRequiredDeliveryDateQuantity(nos)ActualDelivery DateQuantity(nos)Delay inDelivery(days)QuantityDifference(Nos)Reason for Delay /differenceCorrective andPreventive Action1-Jan C10023 A 18-Feb 500 23-Feb 495 5 5Delay in purchasing rawmaterialsROL ordering tobe followed
  • 68. Accident / Near-Miss ReportProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Accident / Near-miss RegisterS.No DateNature ofAccident /Near-miss DepartmentEmployeeInjuredEmployeeCodeDescription of theaccident/near missInjuryTypeFirst-Aid /Visit toHospital Corrective Action Preventive Action1 18-FebMild cut in thehandElectricalWiring Ramesh 238A mild cut in the hand whilecutting the wires using arazor blade minor First Aid First-Aid givenWire-cutters are givento all employees.Usage of bladesbannedNear-Miss ( Incidents) are accidents which didn’t happen, but could have happened on a bad day. A chipflying out of the machine could harm a person some day. It is a near-miss / incident and steps should betaken to prevent this incidents.
  • 69. 5S Audit Report - SortProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.S.No 5S TOPIC CHECK CHECK - DESCRIPTIONDate1 2 3 4 5 6 71SORTAre there any unneeded items? Shopfloor - all areas2Are storage areas clearlydetermined?Areas for : Parking, Pallets, temporary materials storage,delivered goods reception, trash processing, and boxes3Have paths been clearlydefined? Have white and yellow lines been laid down?4 Are there any exposed wires or pipes?5 Are outdoor areas kept clean? Are entrance areas, windows, and paths kept clean?6 Unneeded materials or parts ?Does the inventory or in- process inventory include anyunneeded materials or parts?7Unneeded machines or otherequipment? Are there any unused machines or other equipment around?8 Unneeded jigs, tools or dies? Are there any unused jigs, tools, dies, or similar items around?
  • 70. 5S Audit Report – Set In OrderProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.S.No 5S TOPIC CHECK CHECK - DESCRIPTIONDate1 2 3 4 5 6 71SET IN ORDERHave unneeded items beenmarked? Is it obvious which items have been marked as unnecessary?2 Are there location indicators?Are shelves and other storage areas marked with locationindicators and addresses?3 Are there item indicators ?Do the shelves have signboards showing which items gowhere?4 Are there quantity indicators?Are the maximum and minimum allowable quantitiesindicated?5Demarcation of walkwaysand in- process inventoryareas?Are white lines or other markers used to clearly indicatewalkways and storage areas?6While leaving their workplace, are the employees puttingtheir chairs/stools above the tables7Have improvements beenmade to facilitate jig and toolhandling?Are jigs and tools arranged more rationally to facilitatepicking them up and returning them?
  • 71. 5S Audit Report – ShineProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.S.No 5S TOPIC CHECK CHECK - DESCRIPTIONDate1 2 3 4 5 6 71SHINETrash, water, or oil on floors? Are floors kept shiny and clean?2Are machines covered withshavings and oil? Are the machines wiped clean often?3Is equipment inspectioncombined with equipmentmaintenance ? Do operators clean their machines while checking them?4Have specific cleaning tasksbeen assignedIs there a person responsible for overseeing cleaningoperations?5Has cleanliness become ahabit?Do operators habitually sweep floors and wipe equipmentwithout being told?6Has cleanliness become ahabit?Is the waste falling on the floor ( during the operation ) Ifyes, How to avoid it?7 Is there proper ventilation?Is the room ventilated will enough to be clear of heavy dustand others?8 Is there proper lighting?Is the angle and intensity of the lighting adequate for thework being done?9 Are work clothes clean? Are workers wearing dirty or oil stained work clothes?
  • 72. 5S Audit Report – StandardizeProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.S.No 5S TOPIC CHECK CHECK - DESCRIPTIONDate1 2 3 4 5 6 71STANDARDIZEHave improvements beenmade to prevent things fromgetting dirty?Do the lockers have designed compartments for necessaryitems?2Have rules been establishedfor maintaining the first three5 S?Are the first three 5 s ( seiri,seiton and seiso ) beingmaintained?3 Do workers have uniforms? Do workers wear whatever they want?4Are people punctual abouttheir break times and meetingtimes?Do people keep their appointments and take their breaks ontime ?
  • 73. 5S Audit Report – SustainProperty of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.S.No 5S TOPIC CHECK CHECK - DESCRIPTIONDate1 2 3 4 5 6 71SUSTAINDo people review rules andregulations when theyhappen to meet?Do people check with each other to confirm the rules andcorrect procedures?2Do people obey rules andregulations? Does each worker take rules and regulations seriously?3 Teaching 5S to new Joiners Are the 5S tools and methods taught to the new joiners
  • 74. PRODUCTIONMODULEAn initiative of Hash Management Services LLPA Business Sense PublicationFor more free resources visit www.businessense.inFor any queries / suggestions / requestsCall us: +91 91766 13965orEmail us: support@businessense.in

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