Rapid Site Assessment June 27 2010


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Rapid Site Assessment June 27 2010

  1. 1. Rapid Site Assessment <br />8 Wastes<br />Transportation <br />Inventory <br />Motion <br />Waiting <br />Over processing <br />Over production<br /> Defects <br />Unused Human Potential <br />
  2. 2. Transportation<br />Definition: Any movement of product that does not add value<br />Example: Moving parts in and out of storage, movement of parts between processes <br />Indicator: Batch Production, push production, large storage areas, functional layout <br />Action to take: One Piece Flow, VSM, Point of use storage <br />2<br />2<br />
  3. 3. Inventory<br />Definition: Any material or product that is not needed to satisfy the current customer demand <br />Example: Excess raw materials, work in process, finished goods, <br />Indicator: Long supplier lead times, lack of visible flow, long setups, no ordering process on shop floor <br />Action to take: Pull Systems, One Piece Flow, VSM, SMED <br />3<br />3<br />
  4. 4. Motion<br />Definition: Any movement of people that does not add value <br />Example: Searching for parts/tools/prints, sorting materials, reaching for tools, lifting parts/boxes <br />Indicator: Workplace disorganization, poor workstation design, unsafe workspaces, missing items <br />Action to take: 5S, Hoshin, VSM, Point of Use Storage, Water-Spider <br />4<br />4<br />
  5. 5. Waiting<br />Definition: Idle time created when material, information, people or equipment are not ready <br />Example: Waiting for parts, prints, inspection, machines, repairs, information <br />Indicator: Push production, work imbalance, centralized inspection, high downtime, no visible production plan <br />Action to take: Work Balancing, SMED, TPM, In process Inspection <br />5<br />5<br />
  6. 6. Over processing<br />Definition: Any effort that adds no value from the customers viewpoint <br />Example: Multiple cleaning of parts, over-tight tolerances, paperwork <br />Indicator: Delays between processes, No DFM process involving employees, No standardized work <br />Action to take: VSM, One Piece Flow, Standardized Work <br />6<br />6<br />
  7. 7. Overproduction<br />Definition: Producing more that the customer needs right now <br />Example: Producing to forecast, producing to avoid setups, batch production <br />Indicator: Forecast on shop floor, long setups, inventory to cover breakdowns <br />Action to take: Pull Systems, Work Balancing, Hourly Takt Targets, SMED <br />7<br />7<br />
  8. 8. Defects<br />Definition: Any effort to contain, rework or disposition mistakes or errors <br />Example: Scrap, rework, customer returns, supplier rejects <br />Indicator: Processes not defined and stable, Poor handling and tracking of rejects/rework, Internal and external defect rates not visible <br />Action to take: Standardized Work, DM Process, Customer Focus Area, Shop Floor Problem Solving <br />Upper longeron location in F-15 forward fuselage                                   <br />8<br />8<br />
  9. 9. Unused Human Potential <br />Definition: Any Losses due to lack of utilization of the entire team in continuous improvement <br />Example: No cross-functional teams, top-down management, no suggestion programs <br />Indicator: No Team communication areas, poor understanding of priorities, employee resistance to new ideas <br />Action to take: 5S, Daily Team Meeting, Suggestion System, QRQC <br />9<br />9<br />
  10. 10. 10<br />Example - Scorecard <br />
  11. 11. 11<br />Example - Scorecard <br />