Introduction to Shop Floor management - Janaury 2017

1Marek.Piatkowski@Rogers.com
Shop Floor
Management
Introduction
Thinkingwin, Win, WIN
Shop Floor Management
Introduction
Marek Piatkowski – January 2017

Shop Floor
Management
Introduction
Introduction - Marek Piatkowski
 Professional Background
 Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from
1987-1994
 TPS/Lean Transformation Consulting - since 1994
 Professional Affiliations
 TWI Network – John Shook, Founder
 Lean Enterprise Institute (LEI) – Jim Womack
 Lean Enterprise Academy (LEA) – Daniel Jones
 CCM/CAINTRA – Monterrey, Mexico
 SME, AME, ASQ, CME
 Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com

Shop Floor
Management
Introduction

Shop Floor
Management
Introduction
What is Shop Floor Management
Shop Floor management means developing and controlling:
 Management System:
 Organization - People
 Procedures
 Information
 Management techniques
 A Physical System
 Plant – building and equipment
 Production methods
 Transportation and delivery methods
To economically manufacture products of certain value and quality, in certain volume
and within a certain time period.

Shop Floor
Management
Introduction
Toyota’s Philosophy – Manager’s Role
 In a true TPS environment decision making process should be made at the lowest
possible level of the organization.
 Simple, effective solutions are the most effective
 A manager’s or supervisor’s role consists of leading problem
solving activities in a multi-skilled, cross-functional team
environment
 Managers role is to make sure that for everything that we do there is a well defined
standard process
 Continuous Improvement (Kaizen) activities are management responsibilities.

Shop Floor
Management
Introduction
Two Types of Problems
Sub-standard performance,
abnormal situation
New Standard
New Challenge
1. Daily problems:
deviation from normality
breakdown
quick fixes
2. Long term improvements:
new company objectives
new expectations
looking for a better long term solution

Shop Floor
Management
Introduction
TPS System Rules
Rule 2:
Every customer-supplier
connection must be direct, and
there must be a unmistakable yes-
or-no way to send requests and
receive responses
Rule 1:
All work shall be highly specified
(standardized) as to content,
sequence, timing and outcome
Rule 3:
The pathway for every product and
service must be simple and direct –
flow
Rule 4:
Any improvement must be made in
accordance with the scientific
method, under the guidance of a
teacher, at the lowest possible level
in the organization

Shop Floor
Management
Introduction
TPS Leadership Style
 TPS Leaders have to be quick studies, nimble, and trusting of their employees
 Having deep skills and technological experience is not enough
 Becoming a Leader, at any level, requires the development and utilization of strong
people skills
 TPS Leadership is exclusively about people – you do not lead machines or
processes, you lead people

Shop Floor
Management
Introduction
Two Types of Shop Floor Management Activities
Daily Shop Floor
Management
Shop Floor Continuous
Improvements
Development of Leadership Skills and understanding of Roles
and Responsibilities of a Supervisor or Manager through daily
practices, coaching and On-the-Job Training (OJT).

Shop Floor
Management
Introduction
Daily Shop Floor Management (SFM)
 Basic duties of the Shop Floor personnel (Managers, Group Leaders, Team Leaders)
are to direct and manage resources and processes, so that the company’s quality,
delivery and cost plans and goals are achieved.
 Quality, delivery and costs are three primary production targets based on customer
requirements for components and production. There are also three secondary
targets productivity, safety and morale, which also should be a part of daily
managerial activity.
 SFM are daily activities performed on regular and frequent basis to address and
prevent any existing (current) or any potential problems related to availability and
performance of equipment, materials, people, information and methods.
Daily Shop Floor
Management

Shop Floor
Management
Introduction
Daily Shop Floor Management
 Shop Floor Management (SFM) is about making sure that the systems are working
properly and according to plans
 When there is a problem or a potential of a problem take immediate corrective
action to restore the system to proper function
 SFM focuses on daily performance
 Solve the problem now, so it does not happen again the next hour, shift, day, week,
or month. Only by doing this will we be able to get out of Fire Fighting mode and
into controlled performance
 Walk, stop, look, listen and then ask questions
 If something is not right, correct the problem immediately. Do not walk by it
without action or add it to your “list”. Correct the problem.
Daily Shop Floor
Management

Shop Floor
Management
Introduction
Daily Shop Floor Management - Tools and Methodologies
Tools
 Workplace Organization - 5S
 Visual Management
 Information Centers
 Standardized Work for Leaders
Methodologies
 Daily Team Meetings
 Daily Management Walk About
 Support Team
 Gemba Walks – Process Audit
Daily Shop Floor
Management

Shop Floor
Management
Introduction
Management of Visual Management Indicators
 Identify, review and monitor key control indicators in the following areas:
 Safety: number of near-misses, number of accidents, number of consecutive days
without an accident, ...
 Quality: scrap, process defect rate, rework, repairs, process capability, ...
 Delivery: schedule attainment, quantity, date and sequence, utilization rate, delivery
date, fulfillment rate, daily delivery rate, delay rate,...
 Productivity: quantity produced per unit time or per man-hours, lead times, number
of time each unit is handled by the operator, machine downtime, ...
 Cost: material costs, labor costs, expenses, cost per unit,...
 People: attendance rate, participation in daily meetings, number of submitted
suggestions, job rotation, training, Standardized Work, participation in problem
solving and improvement activities, …
Daily Shop Floor
Management
SAFETY QUALITY DELIVERY PRODUCTIVITY COST PEOPLE

Shop Floor
Management
Introduction
Managing Continuous Improvement (Kaizen) on a Shop Floor
 Continuous Improvement , also know as Kaizen, is the ongoing improvement of
products, services or processes through incremental and breakthrough
improvements.
 Kaizen is a step-by-step approach towards solving problems and identifying
opportunities for continuous improvement
 Continuous Improvement, is a long-term approach to work that systematically
seeks to achieve small, incremental changes in processes in order to improve
efficiency and quality.
 At Toyota Continuous Improvement it is not just a responsibility of a manager or a
supervisors, but also a responsibility of every worker.
 The Continuous Improvement process is reinforced in daily management, daily
problem solving, quality circles, improvement events and A3s.
Improvements

Shop Floor
Management
Introduction
Teamwork - Definition of a Team
 Work Team – a group of people working together towards common goals and
objectives
 Workgroup - a collection of people (employees) in need of a pay check brought
together to make products, provide service and to achieve company objectives
 You need to teach your employees a standardized and a well defined problems
solving and continuous improvement process

Shop Floor
Management
Introduction
Problems with Continuous Improvement Activities
 A common problem with Continuous Improvement is that we look at this as:
 An extra activity - something to do on top of my “Daily Work”
 Middle management says – this is nice, but I have no time for this, I need to run my
operation, I have targets to meet
 Operation people say – Continuous Improvement is OK, but we have no input how
things are improved her, all these Experts are telling us what to do
 Our biggest mistake is that we separate Daily Work from Continuous Improvement
 We look at these two activities as something completely different – they
continuously clash with each other. We look at Continuous Improvement as
something that stops me from doing my daily work. And that is wrong.
 A key to our success is to make Continuous Improvement as a part of our Daily
Business
Improvements

Shop Floor
Management
Introduction
Improvements
Process Improvement SFM - Tools and Methodologies
Tools
 Value Stream Mapping
 PDCA
 Practical Problem Solving
 A3 Report
Methodologies
 Standardized Work
 Kaizen – Continuous Improvement
 Quality Circles
 Improvement Kata

Shop Floor
Management
Introduction
“If you want to teach people a new way of
thinking, don’t bother trying to teach them.
Instead, give them a tool, the use of it will lead
to new ways of thinking”
R. Buckminster Fuller was a 20th century inventor and visionary who did not limit
himself to one field but worked as a 'comprehensive anticipatory design scientist' to
solve global problems. Fuller's ideas and work continue to influence new generations
of designers, architects, scientists and artists working to create a sustainable planet.

Shop Floor
Management
Introduction
Changing the World. One Transformation at a time
This presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproduced
without written permission from:
Marek Piatkowski
W3 Group Canada Inc.
iPhone: 416-235-2631
Cell: 248-207-0416
Marek.Piatkowski@rogers.com
http://twi-network.com

Shop Floor
Management
Introduction
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Introduction to Shop Floor management - Janaury 2017

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