SlideShare a Scribd company logo
Milliken Performance System
Safety
• Safety is the foundation of the performance
system that engages all associates in the
uncompromising pursuit of zero incidents.
What
• Foundation that signals the individuals’
personal well-being comes first, and from there
creates the elements for a high performance
work environment.
Role in the System
• All associates
Who
• Zero incidents, high morale, 100% associate
engagement, trust between associates and
management
Deliverables How
• Total associate ownership
• Hazards, risks identified
• Steering committees
• Sub-committees
• Use of continuous
improvement tools and
methods
• Management as a
resource and coach
Daily Team Maintenance
• DTM provides operators with the knowledge
and skills required to proactively prevent
breakdowns and waste caused by
accelerated equipment deterioration and
abnormalities.
What
• Improved reliability and stability, setting
foundation for other pillar improvements
Role in the System
• Operators, technicians, maintenance,
production leadership
Who
• Reduction in minor stops, breakdowns,
changeover time
Deliverables
How
• 0: Prepare for Restoration
• 1: Restore, Inspect, Understand
• 2: Identify Deterioration & Implement
Solutions
• 3: Establish Cleaning & Lubrication
Standards
• 4: Train Operators to Detect/Correct
Abnormalities
• 5: Apply Practical Application of Methods
• 6: Standardize DTM Throughout the
Location
• 7: Continuously Improve the Process
5S
• Process used to organize and maintain the
workplace environment in order to improve
efficiency and safety, reduce waste, and
eliminate non-value added activities.
What
• Foundational process which establishes the
expectations of discipline and overall
engagement
Role in the System
• All associates
Who
• Improved safety, reduction in non-value
added activities
Deliverables
How
•Model areas
•Separate
•Simplify
•Systematize
•Standardize
•Sustain
Continuous Skills Development
• A standardized training process to ensure
our associates are doing things the right
things, the right way, every single time.
What
• Decrease variation within the production
systems attributed to training opportunities
Role in the System
• All associates
Who
• Reduction in process variation, turnover,
and overall training spend
Deliverables How
• Model areas
• Skills element tree
• Skills assessment
• Associate certification
• Re-training process
• Individual
performance
measurement
Focused Improvement
• FI provides a logical thinking process which
identifies root causes of opportunities in
order to reduce / eliminate losses.
What
• FI Planning and FI projects direct and then
generate resources to fund the performance
system while improving capability of
processes, people and reducing loss
Role in the System
• Operators, technicians, maintenance, process
improvement leadership, engineering
Who
• Reduction in targeted loss areas, increase in
problem-solving confidence
Deliverables
How
• Project approach
following the DMAIC
methodology
•Define
•Measure
•Analyze
•Improve
•Control (and replicate)
Planned Maintenance
• Combination of preventive, predictive, and
zero failure activities. Oversees
maintenance schedule, processes, and
activities to prevent breakdowns before they
occur instead of repairing them after the fact
What
• Foundation for reliability and continuous
improvement
Role in the System
• Maintenance technicians, maintenance
leadership, engineering
Who
• Reduction in breakdowns and spare parts
spend
Deliverables
How
•DTM support
•Lubrication management
•Spare parts management
•Predictive maintenance
•Cost management
•Preventive maintenance
•Skills enhancement
•Zero failure activities
The Advanced Pillars
Building on the Core
Production Control
How
• 7 Step process
•Value stream mapping
•Waste walks
•Improvement projects
•Layered audits
•Demand planning
•Skills enhancement
•Zero failure activities
• Reduce overall system cost through the
elimination of waste identified within the
system. To align the business offering with
manufacturing execution.
What
• Maximization of the velocity of information
and material flow through the process/system.
Role in the System
• Supply chain, production leadership,
operators, technicians, suppliers, customers
Who
• Improve working capital/inventory, variable
conversion cost, capacity utilization, floor
space availability, inventory optimization
Deliverables
Quality Management
How
• 10-Step QM project
implementation
•model project on model
equipment defect
• A systematic methodology to achieve zero
quality defects (not just fewer defects) by
systematically seeking out, identifying, and
eliminating root causes of ALL defects.
What
• Take processes beyond reliability to capability
and the quality process from compliance to
assurance
Role in the System
• Operators, maintenance, quality assurance,
quality leadership
Who
• Reduction in defects, yield loss, waste
Deliverables
Early Equipment Management
• To “design out” losses related to
equipment start-up before they occur by
utilizing existing measurement data &
learnings.
What
• Improved reliability and stability, setting
foundation for other pillar improvements
Role in the System
• Operators, technicians, maintenance,
production leadership, engineering
Who
• Reduction in start-up time, losses and
costs
Deliverables
How
• concept and equipment
planning
• equipment design
• manufacture equipment
• preliminary testing
• install equipment
• commission new
equipment
• full production
implementation
New Product Development
• Cross-functional activity to provide a
continuous flow of innovative, new products
What
• To ensure a robust stream of new products
into the system that creates value for the
company and customer
Role in the System
• Customers, suppliers, business, research,
manufacturing, supply chain
Who
• Shortened delivery cycle, high quality zero
loss start-ups, meet/beat targeted costs,
100% on-time delivery
Deliverables
How
• 6 Step Process
• Discovery & concept
development
• Product design requirements
• Design for manufacturing
• Adoption & launch
• Scale-up &
commercialization
Pillar Relationship Matrix
5S DTM CSD PM FI QM PC EEM NPD
5S ● ● ● ● ● ● ● ●
DTM ● ● ● ● ● ● ● ●
CSD ● ● ● ● ● ● ● ●
PM ● ● ● ● ● ● ● ●
FI ● ● ● ● ● ● ● ●
QM ● ● ● ● ● ● ● ●
PC ● ● ● ● ● ● ● ●
EEM ● ● ● ● ● ● ● ●
NPD ● ● ● ● ● ● ● ●
= interaction
= major impact on success
Energy
Inventory
Obsolescence
Quality / reworks
Waste
Training
Inspection & Testing
Material Handling
Planning
PM & Cleaning Downtime
Speed Loss
Minor Stops
Start-up / shut down
Change time
Breakdowns
NPD
EEM
PC
QM
PM
FI
CSD
DTM
5S
Energy
Inventory
Obsolescence
Quality /
Waste
Training
Inspection & Testing
Material Handling
Planning
PM & Cleaning Downtime
Speed Loss
Minor Stops
Start-up / shut down
Change time
Breakdowns
5S
Some impact
Some impact Medium impact
Medium impact Major impact
Major impact Future impact
Future impact
Pillar to Loss Relationship Matrix

More Related Content

Similar to Miliken Performance system.pdf

AReNA - Debate Is Machine Learning Mature Enough
AReNA - Debate Is Machine Learning Mature EnoughAReNA - Debate Is Machine Learning Mature Enough
AReNA - Debate Is Machine Learning Mature Enough
Hernan Huwyler, MBA CPA
 
Adaptive case study on setting up of PMO for large it organization
Adaptive case study on setting up of PMO for large it organizationAdaptive case study on setting up of PMO for large it organization
Adaptive case study on setting up of PMO for large it organization
LN Mishra CBAP
 
Operational Excellence in Oil and Gas Loss Prevention
Operational Excellence in Oil and Gas Loss PreventionOperational Excellence in Oil and Gas Loss Prevention
Operational Excellence in Oil and Gas Loss Prevention
Michael Marshall, PE
 
Beating the product credit crunch
Beating the product credit crunchBeating the product credit crunch
Beating the product credit crunch
Stephen Williams
 
Digital transformation through devops dod indianapolis
Digital transformation through devops dod indianapolisDigital transformation through devops dod indianapolis
Digital transformation through devops dod indianapolis
Peter Varhol
 
Data center engineering operations
Data center engineering operationsData center engineering operations
Data center engineering operations
Jagbir Sangwan
 
Artificial Intelligence (AI) the Good the Bad and the Ugly of Manufacturing O...
Artificial Intelligence (AI) the Good the Bad and the Ugly of Manufacturing O...Artificial Intelligence (AI) the Good the Bad and the Ugly of Manufacturing O...
Artificial Intelligence (AI) the Good the Bad and the Ugly of Manufacturing O...
Luis Cabrera
 
1c mukund kamdar-resume rel-6 p
1c mukund kamdar-resume rel-6 p1c mukund kamdar-resume rel-6 p
1c mukund kamdar-resume rel-6 p
Mukund Kamdar
 
Process innovation & value chain
Process innovation & value chainProcess innovation & value chain
Process innovation & value chain
cc85
 
Asset Managment
Asset ManagmentAsset Managment
Asset Managment
Michelle Kleiber-Viglione
 
DECIDE4ACTION Presentation
DECIDE4ACTION PresentationDECIDE4ACTION Presentation
DECIDE4ACTION Presentation
Richard Bergeron
 
SimuWorks:
SimuWorks: SimuWorks:
SimuWorks:
Robert P Beres
 
Quality assurance and management, software engineering
Quality assurance and management, software engineeringQuality assurance and management, software engineering
Quality assurance and management, software engineering
Rupesh Vaishnav
 
Preventive Maintenance Best Practices workshop Brochure
Preventive Maintenance Best Practices workshop BrochurePreventive Maintenance Best Practices workshop Brochure
Preventive Maintenance Best Practices workshop Brochure
Ricky Smith CMRP, CMRT
 
Quality control and quality assurance
Quality control and quality assuranceQuality control and quality assurance
Quality control and quality assurance
Leola Ramirez
 
Risk management & compliance with xyea october 2012
Risk management & compliance with xyea october 2012Risk management & compliance with xyea october 2012
Risk management & compliance with xyea october 2012Xyea
 
Transform your IT into a Strategic Asset
Transform your IT into a Strategic AssetTransform your IT into a Strategic Asset
Transform your IT into a Strategic AssetYJT Solutions
 
Questions for successful test automation projects
Questions for successful test automation projectsQuestions for successful test automation projects
Questions for successful test automation projects
Daniel Ionita
 

Similar to Miliken Performance system.pdf (20)

AReNA - Debate Is Machine Learning Mature Enough
AReNA - Debate Is Machine Learning Mature EnoughAReNA - Debate Is Machine Learning Mature Enough
AReNA - Debate Is Machine Learning Mature Enough
 
Adaptive case study on setting up of PMO for large it organization
Adaptive case study on setting up of PMO for large it organizationAdaptive case study on setting up of PMO for large it organization
Adaptive case study on setting up of PMO for large it organization
 
Mitzi_Heinrich_Resume
Mitzi_Heinrich_ResumeMitzi_Heinrich_Resume
Mitzi_Heinrich_Resume
 
Ch9 Jit
Ch9 JitCh9 Jit
Ch9 Jit
 
Operational Excellence in Oil and Gas Loss Prevention
Operational Excellence in Oil and Gas Loss PreventionOperational Excellence in Oil and Gas Loss Prevention
Operational Excellence in Oil and Gas Loss Prevention
 
Beating the product credit crunch
Beating the product credit crunchBeating the product credit crunch
Beating the product credit crunch
 
Digital transformation through devops dod indianapolis
Digital transformation through devops dod indianapolisDigital transformation through devops dod indianapolis
Digital transformation through devops dod indianapolis
 
Data center engineering operations
Data center engineering operationsData center engineering operations
Data center engineering operations
 
Artificial Intelligence (AI) the Good the Bad and the Ugly of Manufacturing O...
Artificial Intelligence (AI) the Good the Bad and the Ugly of Manufacturing O...Artificial Intelligence (AI) the Good the Bad and the Ugly of Manufacturing O...
Artificial Intelligence (AI) the Good the Bad and the Ugly of Manufacturing O...
 
1c mukund kamdar-resume rel-6 p
1c mukund kamdar-resume rel-6 p1c mukund kamdar-resume rel-6 p
1c mukund kamdar-resume rel-6 p
 
Process innovation & value chain
Process innovation & value chainProcess innovation & value chain
Process innovation & value chain
 
Asset Managment
Asset ManagmentAsset Managment
Asset Managment
 
DECIDE4ACTION Presentation
DECIDE4ACTION PresentationDECIDE4ACTION Presentation
DECIDE4ACTION Presentation
 
SimuWorks:
SimuWorks: SimuWorks:
SimuWorks:
 
Quality assurance and management, software engineering
Quality assurance and management, software engineeringQuality assurance and management, software engineering
Quality assurance and management, software engineering
 
Preventive Maintenance Best Practices workshop Brochure
Preventive Maintenance Best Practices workshop BrochurePreventive Maintenance Best Practices workshop Brochure
Preventive Maintenance Best Practices workshop Brochure
 
Quality control and quality assurance
Quality control and quality assuranceQuality control and quality assurance
Quality control and quality assurance
 
Risk management & compliance with xyea october 2012
Risk management & compliance with xyea october 2012Risk management & compliance with xyea october 2012
Risk management & compliance with xyea october 2012
 
Transform your IT into a Strategic Asset
Transform your IT into a Strategic AssetTransform your IT into a Strategic Asset
Transform your IT into a Strategic Asset
 
Questions for successful test automation projects
Questions for successful test automation projectsQuestions for successful test automation projects
Questions for successful test automation projects
 

Recently uploaded

HYDROPOWER - Hydroelectric power generation
HYDROPOWER - Hydroelectric power generationHYDROPOWER - Hydroelectric power generation
HYDROPOWER - Hydroelectric power generation
Robbie Edward Sayers
 
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptx
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxCFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptx
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptx
R&R Consult
 
Immunizing Image Classifiers Against Localized Adversary Attacks
Immunizing Image Classifiers Against Localized Adversary AttacksImmunizing Image Classifiers Against Localized Adversary Attacks
Immunizing Image Classifiers Against Localized Adversary Attacks
gerogepatton
 
ethical hacking in wireless-hacking1.ppt
ethical hacking in wireless-hacking1.pptethical hacking in wireless-hacking1.ppt
ethical hacking in wireless-hacking1.ppt
Jayaprasanna4
 
block diagram and signal flow graph representation
block diagram and signal flow graph representationblock diagram and signal flow graph representation
block diagram and signal flow graph representation
Divya Somashekar
 
H.Seo, ICLR 2024, MLILAB, KAIST AI.pdf
H.Seo,  ICLR 2024, MLILAB,  KAIST AI.pdfH.Seo,  ICLR 2024, MLILAB,  KAIST AI.pdf
H.Seo, ICLR 2024, MLILAB, KAIST AI.pdf
MLILAB
 
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdf
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfCOLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdf
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdf
Kamal Acharya
 
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...
Amil Baba Dawood bangali
 
Standard Reomte Control Interface - Neometrix
Standard Reomte Control Interface - NeometrixStandard Reomte Control Interface - Neometrix
Standard Reomte Control Interface - Neometrix
Neometrix_Engineering_Pvt_Ltd
 
MCQ Soil mechanics questions (Soil shear strength).pdf
MCQ Soil mechanics questions (Soil shear strength).pdfMCQ Soil mechanics questions (Soil shear strength).pdf
MCQ Soil mechanics questions (Soil shear strength).pdf
Osamah Alsalih
 
road safety engineering r s e unit 3.pdf
road safety engineering  r s e unit 3.pdfroad safety engineering  r s e unit 3.pdf
road safety engineering r s e unit 3.pdf
VENKATESHvenky89705
 
addressing modes in computer architecture
addressing modes  in computer architectureaddressing modes  in computer architecture
addressing modes in computer architecture
ShahidSultan24
 
The role of big data in decision making.
The role of big data in decision making.The role of big data in decision making.
The role of big data in decision making.
ankuprajapati0525
 
Automobile Management System Project Report.pdf
Automobile Management System Project Report.pdfAutomobile Management System Project Report.pdf
Automobile Management System Project Report.pdf
Kamal Acharya
 
LIGA(E)11111111111111111111111111111111111111111.ppt
LIGA(E)11111111111111111111111111111111111111111.pptLIGA(E)11111111111111111111111111111111111111111.ppt
LIGA(E)11111111111111111111111111111111111111111.ppt
ssuser9bd3ba
 
Railway Signalling Principles Edition 3.pdf
Railway Signalling Principles Edition 3.pdfRailway Signalling Principles Edition 3.pdf
Railway Signalling Principles Edition 3.pdf
TeeVichai
 
Student information management system project report ii.pdf
Student information management system project report ii.pdfStudent information management system project report ii.pdf
Student information management system project report ii.pdf
Kamal Acharya
 
ASME IX(9) 2007 Full Version .pdf
ASME IX(9)  2007 Full Version       .pdfASME IX(9)  2007 Full Version       .pdf
ASME IX(9) 2007 Full Version .pdf
AhmedHussein950959
 
Quality defects in TMT Bars, Possible causes and Potential Solutions.
Quality defects in TMT Bars, Possible causes and Potential Solutions.Quality defects in TMT Bars, Possible causes and Potential Solutions.
Quality defects in TMT Bars, Possible causes and Potential Solutions.
PrashantGoswami42
 
Gen AI Study Jams _ For the GDSC Leads in India.pdf
Gen AI Study Jams _ For the GDSC Leads in India.pdfGen AI Study Jams _ For the GDSC Leads in India.pdf
Gen AI Study Jams _ For the GDSC Leads in India.pdf
gdsczhcet
 

Recently uploaded (20)

HYDROPOWER - Hydroelectric power generation
HYDROPOWER - Hydroelectric power generationHYDROPOWER - Hydroelectric power generation
HYDROPOWER - Hydroelectric power generation
 
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptx
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptxCFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptx
CFD Simulation of By-pass Flow in a HRSG module by R&R Consult.pptx
 
Immunizing Image Classifiers Against Localized Adversary Attacks
Immunizing Image Classifiers Against Localized Adversary AttacksImmunizing Image Classifiers Against Localized Adversary Attacks
Immunizing Image Classifiers Against Localized Adversary Attacks
 
ethical hacking in wireless-hacking1.ppt
ethical hacking in wireless-hacking1.pptethical hacking in wireless-hacking1.ppt
ethical hacking in wireless-hacking1.ppt
 
block diagram and signal flow graph representation
block diagram and signal flow graph representationblock diagram and signal flow graph representation
block diagram and signal flow graph representation
 
H.Seo, ICLR 2024, MLILAB, KAIST AI.pdf
H.Seo,  ICLR 2024, MLILAB,  KAIST AI.pdfH.Seo,  ICLR 2024, MLILAB,  KAIST AI.pdf
H.Seo, ICLR 2024, MLILAB, KAIST AI.pdf
 
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdf
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdfCOLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdf
COLLEGE BUS MANAGEMENT SYSTEM PROJECT REPORT.pdf
 
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...
NO1 Uk best vashikaran specialist in delhi vashikaran baba near me online vas...
 
Standard Reomte Control Interface - Neometrix
Standard Reomte Control Interface - NeometrixStandard Reomte Control Interface - Neometrix
Standard Reomte Control Interface - Neometrix
 
MCQ Soil mechanics questions (Soil shear strength).pdf
MCQ Soil mechanics questions (Soil shear strength).pdfMCQ Soil mechanics questions (Soil shear strength).pdf
MCQ Soil mechanics questions (Soil shear strength).pdf
 
road safety engineering r s e unit 3.pdf
road safety engineering  r s e unit 3.pdfroad safety engineering  r s e unit 3.pdf
road safety engineering r s e unit 3.pdf
 
addressing modes in computer architecture
addressing modes  in computer architectureaddressing modes  in computer architecture
addressing modes in computer architecture
 
The role of big data in decision making.
The role of big data in decision making.The role of big data in decision making.
The role of big data in decision making.
 
Automobile Management System Project Report.pdf
Automobile Management System Project Report.pdfAutomobile Management System Project Report.pdf
Automobile Management System Project Report.pdf
 
LIGA(E)11111111111111111111111111111111111111111.ppt
LIGA(E)11111111111111111111111111111111111111111.pptLIGA(E)11111111111111111111111111111111111111111.ppt
LIGA(E)11111111111111111111111111111111111111111.ppt
 
Railway Signalling Principles Edition 3.pdf
Railway Signalling Principles Edition 3.pdfRailway Signalling Principles Edition 3.pdf
Railway Signalling Principles Edition 3.pdf
 
Student information management system project report ii.pdf
Student information management system project report ii.pdfStudent information management system project report ii.pdf
Student information management system project report ii.pdf
 
ASME IX(9) 2007 Full Version .pdf
ASME IX(9)  2007 Full Version       .pdfASME IX(9)  2007 Full Version       .pdf
ASME IX(9) 2007 Full Version .pdf
 
Quality defects in TMT Bars, Possible causes and Potential Solutions.
Quality defects in TMT Bars, Possible causes and Potential Solutions.Quality defects in TMT Bars, Possible causes and Potential Solutions.
Quality defects in TMT Bars, Possible causes and Potential Solutions.
 
Gen AI Study Jams _ For the GDSC Leads in India.pdf
Gen AI Study Jams _ For the GDSC Leads in India.pdfGen AI Study Jams _ For the GDSC Leads in India.pdf
Gen AI Study Jams _ For the GDSC Leads in India.pdf
 

Miliken Performance system.pdf

  • 2. Safety • Safety is the foundation of the performance system that engages all associates in the uncompromising pursuit of zero incidents. What • Foundation that signals the individuals’ personal well-being comes first, and from there creates the elements for a high performance work environment. Role in the System • All associates Who • Zero incidents, high morale, 100% associate engagement, trust between associates and management Deliverables How • Total associate ownership • Hazards, risks identified • Steering committees • Sub-committees • Use of continuous improvement tools and methods • Management as a resource and coach
  • 3. Daily Team Maintenance • DTM provides operators with the knowledge and skills required to proactively prevent breakdowns and waste caused by accelerated equipment deterioration and abnormalities. What • Improved reliability and stability, setting foundation for other pillar improvements Role in the System • Operators, technicians, maintenance, production leadership Who • Reduction in minor stops, breakdowns, changeover time Deliverables How • 0: Prepare for Restoration • 1: Restore, Inspect, Understand • 2: Identify Deterioration & Implement Solutions • 3: Establish Cleaning & Lubrication Standards • 4: Train Operators to Detect/Correct Abnormalities • 5: Apply Practical Application of Methods • 6: Standardize DTM Throughout the Location • 7: Continuously Improve the Process
  • 4. 5S • Process used to organize and maintain the workplace environment in order to improve efficiency and safety, reduce waste, and eliminate non-value added activities. What • Foundational process which establishes the expectations of discipline and overall engagement Role in the System • All associates Who • Improved safety, reduction in non-value added activities Deliverables How •Model areas •Separate •Simplify •Systematize •Standardize •Sustain
  • 5. Continuous Skills Development • A standardized training process to ensure our associates are doing things the right things, the right way, every single time. What • Decrease variation within the production systems attributed to training opportunities Role in the System • All associates Who • Reduction in process variation, turnover, and overall training spend Deliverables How • Model areas • Skills element tree • Skills assessment • Associate certification • Re-training process • Individual performance measurement
  • 6. Focused Improvement • FI provides a logical thinking process which identifies root causes of opportunities in order to reduce / eliminate losses. What • FI Planning and FI projects direct and then generate resources to fund the performance system while improving capability of processes, people and reducing loss Role in the System • Operators, technicians, maintenance, process improvement leadership, engineering Who • Reduction in targeted loss areas, increase in problem-solving confidence Deliverables How • Project approach following the DMAIC methodology •Define •Measure •Analyze •Improve •Control (and replicate)
  • 7. Planned Maintenance • Combination of preventive, predictive, and zero failure activities. Oversees maintenance schedule, processes, and activities to prevent breakdowns before they occur instead of repairing them after the fact What • Foundation for reliability and continuous improvement Role in the System • Maintenance technicians, maintenance leadership, engineering Who • Reduction in breakdowns and spare parts spend Deliverables How •DTM support •Lubrication management •Spare parts management •Predictive maintenance •Cost management •Preventive maintenance •Skills enhancement •Zero failure activities
  • 9. Production Control How • 7 Step process •Value stream mapping •Waste walks •Improvement projects •Layered audits •Demand planning •Skills enhancement •Zero failure activities • Reduce overall system cost through the elimination of waste identified within the system. To align the business offering with manufacturing execution. What • Maximization of the velocity of information and material flow through the process/system. Role in the System • Supply chain, production leadership, operators, technicians, suppliers, customers Who • Improve working capital/inventory, variable conversion cost, capacity utilization, floor space availability, inventory optimization Deliverables
  • 10. Quality Management How • 10-Step QM project implementation •model project on model equipment defect • A systematic methodology to achieve zero quality defects (not just fewer defects) by systematically seeking out, identifying, and eliminating root causes of ALL defects. What • Take processes beyond reliability to capability and the quality process from compliance to assurance Role in the System • Operators, maintenance, quality assurance, quality leadership Who • Reduction in defects, yield loss, waste Deliverables
  • 11. Early Equipment Management • To “design out” losses related to equipment start-up before they occur by utilizing existing measurement data & learnings. What • Improved reliability and stability, setting foundation for other pillar improvements Role in the System • Operators, technicians, maintenance, production leadership, engineering Who • Reduction in start-up time, losses and costs Deliverables How • concept and equipment planning • equipment design • manufacture equipment • preliminary testing • install equipment • commission new equipment • full production implementation
  • 12. New Product Development • Cross-functional activity to provide a continuous flow of innovative, new products What • To ensure a robust stream of new products into the system that creates value for the company and customer Role in the System • Customers, suppliers, business, research, manufacturing, supply chain Who • Shortened delivery cycle, high quality zero loss start-ups, meet/beat targeted costs, 100% on-time delivery Deliverables How • 6 Step Process • Discovery & concept development • Product design requirements • Design for manufacturing • Adoption & launch • Scale-up & commercialization
  • 13. Pillar Relationship Matrix 5S DTM CSD PM FI QM PC EEM NPD 5S ● ● ● ● ● ● ● ● DTM ● ● ● ● ● ● ● ● CSD ● ● ● ● ● ● ● ● PM ● ● ● ● ● ● ● ● FI ● ● ● ● ● ● ● ● QM ● ● ● ● ● ● ● ● PC ● ● ● ● ● ● ● ● EEM ● ● ● ● ● ● ● ● NPD ● ● ● ● ● ● ● ● = interaction = major impact on success
  • 14. Energy Inventory Obsolescence Quality / reworks Waste Training Inspection & Testing Material Handling Planning PM & Cleaning Downtime Speed Loss Minor Stops Start-up / shut down Change time Breakdowns NPD EEM PC QM PM FI CSD DTM 5S Energy Inventory Obsolescence Quality / Waste Training Inspection & Testing Material Handling Planning PM & Cleaning Downtime Speed Loss Minor Stops Start-up / shut down Change time Breakdowns 5S Some impact Some impact Medium impact Medium impact Major impact Major impact Future impact Future impact Pillar to Loss Relationship Matrix