Adaptive production systems rev 19 june 2017 franck vermet
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What does it take to adapt in today's world? Implement industrial Darwinism. It is not the strongest that survives, but the most adaptable. This presentation will show you how to deploy Adaptive Production Systems to reach continuous improvement. This is an evolutionary step to simplify the complex methods of Lean and Six Sigma. This is achieved by developing a different behaviour throughout the organization: coaching people to simplify their life at work results in ever improving performance. The paradygm here is that simplifying people's life at work will result in performance improvements, as opposed to the traditional push approach for improvement to expect better results.
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Whether you are producing cooking oil, baby oil or motor oil, one matter is constant, if you are trying to implement a quality system; you are competing with other projects for finite corporate resources. One of the most effective ways to compete for those resources and demonstrate project success is to be able to quantitatively demonstrate Return On Investment (ROI).
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• What are common ROI targets and how may they be adapted to your plant requirements.
• How to quantify ROI.
Quality systems and operations typically deliver substantial cost benefits and rapid returns. Properly done, ROI modeling will not only enable you to obtain the necessary resources to develop your projects, but will also provide an ongoing basis to justify the quality management operations.
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• An assembly process where management must determine which defects are most amenable to process improvement and will provide the greatest return for the effort.
• A food processor facing product giveaway by overfilling. How can the processor improve the filling performance and calculate the ROI of the effort?
• A high-speed process that makes multiple products has historically required long startup and change-over times to become stable enough for normal production. How can the producer reduce startup time and waste?
Applying SPC to your production process is one of the quickest ways to realize a return from your quality system. SPC-based process improvements reduce variation and make further improvements possible.
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Adaptive production systems rev 19 june 2017 franck vermet
- 1. Adaptive Production Systems® Franck Vermet 2016
- 2. Adapt = Improve = change Behavior
- 3. Production Systems Basics INPUTS OUTPUTSPROCESS Supplier Customer a
- 5. Standard Process Steps INPUTS OUTPUTSPROCESS Safety Morale Quality Time CostStore Setup Add value Check Transport a
- 7. PROCESSINPUTS OUTPUTSCheck Structure the system Process mapping Critical Skills identification, capture and transfer Instruction a
- 8. PROCESSINPUTS OUTPUTSCheck Discover problems Quantitative: Data analysis Qualitative: Shop floor a
- 9. PROCESSINPUTS OUTPUTSCheck Implement a reactive feedback loop Root Cause Analysis / Containment Problem solving a
- 10. PROCESSINPUTS OUTPUTSCheck Stabilize the System Instruction Problem solving a
- 11. PROCESSINPUTS OUTPUTSCheck Stabilize the System: Lean methodology Instruction Problem solving The 7 wastes = 3 for Quality + 4 for Time = $ a
- 13. PROCESSINPUTS OUTPUTSCheck Stabilize the System: Lean methodology Instruction Problem solving The 7 wastes = 3 for Quality + 4 for Time = $ The Lean Toolbox = Surface and fix systemic problems a
- 15. PROCESSINPUTS OUTPUTSCheck Stabilize the System: Lean methodology (PDCA) Instruction Problem solving The 7 wastes = 3 for Quality + 4 for Time = $ The Lean Toolbox = Surface and fix systemic problems a
- 16. PROCESSINPUTS OUTPUTSCheck Stabilize the System: Six Sigma methodology (DMAIC) Instruction Problem solving Measure Improve Analyze Control Define the problem Sigma level Defects (ppm) Defects (%) 1 691462 69% 2 308538 31% 3 66807 6.7% 4 6210 0.6% 5 233 0.02% 6 3 0.0003% a
- 17. PROCESSINPUTS OUTPUTSCheck Instruction Problem solving Measure Improve Analyze Control Stabilize the System: Six Sigma methodology (DMAIC) Define the problem a
- 18. Adaptive Production Systems PROCESSINPUTS OUTPUTSCheck Process improvement Proactive Loop: Instruction Problem solving a
- 19. Adaptive Production Systems = 6 basic training modules + coaching PROCESSINPUTS OUTPUTSCheck Instruction Problem solving Process improvement Process / heat mapping Skills identification, capture and transfer 1 2 6 5 Quantitative: Data analysis Qualitative: Shop floor walk 3 4 a
- 20. Deploy Adaptive Production Systems The What = build people who build the System - Long term By the Why = solving short term Cost, Quality or Time problems How? m
- 21. The What = build people who build the System - Long term By the Why = solving short term Cost, Quality or Time problems How? Deploy Adaptive Production Systems