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Shop Floor Management I I


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Shop Floor Management I I

  1. 1. Shop Floor Management<br />
  2. 2. Chapter 5<br />Discuss the management role in upgrading everybody’s skills within an organization.<br />
  3. 3. Chapter 5<br />Role of manager is important to upgrade skills of their people.<br />However, many people don’t know or practice how to practice this.<br />Typical Management Problems in Upgrading People’s Skills<br />So we don’t take responsible or allocate sufficient time for education, leaving people behind.<br />If we spend time for chasing fire and not upgrading skills, our future will be limited.<br />
  4. 4. Chapter 5<br />Not just as individuals, we need to think of ways to work on important jobs as group as well<br />Ideas for Managers and Staffs in Upgrading People’s Skills<br />Recognizing important of upgrading skills, we go through cycle.<br />Plan to provide training (plan)<br />Execute training (do)<br />Review how the idea is generated (check)<br />
  5. 5. Chapter 5<br />Share applications of skills and provide feedback to improve training process (act)<br />Go back to item 1 and continue cycle<br />Even this principle is simple, the execution can make difficluties.<br />We need to find ways to train people with less involvement of outside specialists or centralized training organizations.<br />The training program should simplified and done right on the shop floor.<br />As we do our jobs and gain experience over time, we tend to develop habits<br />
  6. 6. Chapter 5<br />But if we depend on our habits, we can’t meet the requirements of today’s business.<br />We need to see, listen and learn without prejudice.<br />If our judgment skewed, it difficult to access things properly.<br />Therefore it better to start out with no knowledge, to look at the situation afresh and learn to use own wisdom to the maximum.<br />
  7. 7. Chapter 6<br />In order to promote improvement activities, we need to be able to expose problems, identify problems areas and do problem-solving effectively.<br />
  8. 8. Chapter 6<br />It is important to expose problems effectively so that suitable tools for solving can be used.<br />Exposing problems effectively will not only help to maintain standard but also help to guide better and involve everybody in improvement.<br />For organization as a team, problems should be not only dealt with in specific areas but also throughout the company. <br />Since any organization have its own mission, objectives and plan of action to achieve, problems need to be expose in each specific area so that problem solving process take place.<br />Inventory can cover problems and prevent us from continuous improvement.<br />
  9. 9. Chapter 6<br />We should reduce the inventory level to uncover problems and address problems.<br />As we take away these wasted or underutilized resources, we can utilize the resources better and focus to attain our goals.<br />So as we try to reduce extra resources, we should be able to make improvement.<br />Key reasons for reducing inventory<br />Exposing problems rather than covering up<br />Focusing attention on problems<br />Utilizing resources constructively<br />
  10. 10. Chapter 6<br />If there are people who do not know about problems, it may be sign that they can’t utilize their resources well to make continuous improvement.<br />Instead of solving problems themselves, management should think of problem-solving approaches so that more people can participate.<br />If these tools are introduced unclearly, it can hurt the organization and people.<br />Therefore coordination, support and feedback from management and education become very important.<br />
  11. 11. Chapter 7<br />How to practice suggestion program effectively in your organization?<br />
  12. 12. Chapter 7<br />Suggestion program is one of the problem-solving activities.<br />However suggestion program can face failure because management think potential of people’s talent too lightly and lack of willpower in management.<br />There are some facts for why suggestion program fails<br />Jump into problems without much preparation<br />Accomplishments are not shared within people<br />Don’t get feedback<br />In spite of difficulties, there are many successful suggestion programs.<br />
  13. 13. Chapter 7<br />Monetary incentives should be limited if we focus on involving total work force.<br />In order to get everybody’s participation, suggestions can be shared in meeting or newsletter.<br />General recommendation is to focus on small improvement of people involvement, no of suggestions increased and improve quality of suggestion.<br />Implementing an effective suggestion program has four phase.<br />Preparation phase<br />Startup phase<br />
  14. 14. Chapter 7<br />Expansion phase<br />Further phase<br />Some want to share their ideas through suggestion program.<br />The benefits of suggestion program<br />Make easy to communicate each others<br />Expose areas where support are needed<br />By keeping individual records, each can see the progress<br />
  15. 15. Chapter 8<br />Why are leaders important for continuous improvement in an organization? Discuss the roles of leader.<br />
  16. 16. Chapter 8<br />Leading people is more important than managing people.<br />So managers need to develop a broad understanding of business and high level of leadership skills.<br />The more people improve skills and gain confidence, the more manager can delegate responsibility.<br />We should see manager as a leader and employees as a customer.<br />Leadership can’t be found at traditional organization because it is situational.<br />Leader have strong desire to accomplish than the members.<br />
  17. 17. Chapter 8<br />Guiding improvement process at shop floor<br />Think of small improvement fist<br />Persuade someone to think about improvement<br />Guide people to think about what they can do to improve<br />Find ways to support and implement ideas<br />Follow up the implementation<br />Sharing success<br />If company have great success, the leader should share this achievement.<br />That’s point out everybody is working together to accomplish the mission.<br />
  18. 18. Chapter 8<br />Improving communication at the shop floor<br />Absence of meetings indicate that there is no close linkage between management and people at the shop floor.<br />Recognize and reward people<br />Positive reinforcement can motivate the people at the shop floor.<br />So leaders try to find the opportunities for reorganization and reward.<br />Leaders feel that important part of their job is to provide opportunities to celebrate success and encourage people to move forward.<br />
  19. 19. Chapter 9<br />If your company is facing failure due to the weakness in control system, how will you overcome it?<br />
  20. 20. Chapter 9<br />If company face failure, management should try to use PDCA (plan-do-check-act) cycle.<br />The time it takes to go through the cycle will differ depending on the nature of work and needs.<br />In reality, there are different stages of progress to digest this cycle.<br />As more checking and acting take place, planning should become easier.<br />PDCA model provide management with clarity and drive organization forward.<br />
  21. 21. Chapter 9<br />Another way for overcoming weakness is managing improvement activities with control points.<br />To establish clear checkpoints and network of control, management should understand concept of control points.<br />Depend of characteristics, control points are divided into control items at outcome of process and check items at the root cause of process.<br />Same concept can be used for either manufacturing and management.<br />