1. How to Implement Sustainable 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
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