Downloaded 12 times
Uploaded byDavid McDonald
Operations Excellence
This document provides a roadmap for improving manufacturing performance through a structured approach. It begins with aligning goals and objectives from senior leadership down to the shop floor. The next step is to focus on early, measurable improvements to drive results. This involves deploying new tools and capabilities as well as tracking progress and implementing corrective actions. Key steps include pre-production reviews to plan for issues, setting shift-by-shift performance targets, taking immediate corrective actions, and conducting post-production reviews to identify root causes and update documentation. The overall goal is to decrease process times, increase schedule attainment, and reduce costs.
Operations Excellence
- 1. How to ImplementSustainable Manufacturing Performance Improvements A structured, proven approach will accelerate measureable improvements Change Solutions Group, LLP, 2015 A Roadmap for Improved Manufacturing Performance Manufacturing Performance Challenges 790 236 214 192 118 72 72 64 64 53 30 20 0 100 200 300 400 500 600 700 800 900 Production Losses (Hrs) Loss Code Sum of Hrs of Delay Breakthrough Goals Project Priorities Annual Objectives Targets& Measures Actions & Resources Align Goals and Objectives From Corner Office to Shop Floor Focused-Improvements to Drive Early Results Productivity Improvement Process Deploy New Tools & Capabilities System for Managing Track Progress & Implement Corrective Actions KPI Scorecard Excessive Rework Long Process Times Low Product Yields Unfavorable Cost Variances Ineffective Supervision Operator Errors Material Shortages Materials Suppliers Planning Inventory “Stockout” Of Raw Materials Order Level Status Dynamic Ordering for “other” sites Not Released Retest Dates Change in Plans Stock Level Unknown Locations (consumables) Mat’l Off Spec Pending Shipment Notice Delays Order Not Confirmed Long LTs Not Accurate In-Out-In to Warehouse Materials used for Other Inconsistent SAP Codes “X” Conditionally Released At CustomsTiming In Lab Lab Does Not Have Sample Common Expiration Dates/Times Sales & Operations Plan Master Production Schedule Weekly Planning Meeting Daily Production Status Review Shift-by-Shift Schedules KPI Tracking & Reporting Weekly Production Performance & Corrective Actions Summary of Results Costs $1.4 M USD Process Times 24 % Decrease Schedule Attainment 16% Increase 1 2 3 4 5 Pre-Production Review Review known issues & risks Develop contingency plans Communicate across shifts Plan to Standard Campaign size Shop Floor Controls Shift-by-Shift Performance Targets Operator Engagement & Feedback Immediate Corrective Actions Post-Production Review Review performance to standard (Yield, Labor & Equipment Hrs) Document cycle time losses Identify Root Cause Update documentation Pre-Campaign Meeting Focus Products Implement Improvements www.ChangeSolutionsGroup.com