Competitive Edge…
- Reduce Development Lead time to MFG
- Reduce Cost-Material and Labor
- Reduce Inventory Raw, WIP, FG
- Improve Space utilization- Sales $/Sq FT
- Reduce Shipping Lead time to Customers
- Increase Sales Revenue
Business Objectives and Goals!
- What are they?
- Key Managers meet every 2 weeks
- Establish Goals for each manager to report in the meeting
- Meeting is to update management team and evaluate performance
- How are they communicated to the TEAM?
- Monthly Review Meetings
- Where are they posted for viewing?
- Visual Location in MFG and OFFICE
- How often are they updated?
- Weekly Postings with Monthly Presentations
- How are they tracked?
- Excel, ERP systems, Cloud Based Server
- Clearly Communicate to TEAM that Lean initiatives (PACE-Productivity And Capacity Excellence) will be a road map to retaining jobs and improving Market Share
Key Manufacturing Objectives
- Reduce Floor Space!
- Combine Similar Operations
- Reduce Finished Goods Inventory!
- Implement FIFO system
- Implement Kan-Ban System
- Introduce Live Broadcast System to Work Center
- Introduce Bar Coding
- Reduce Product Cost! Parts and Labor!
- Resource poor performing suppliers-Cost/Quality
- Combine operation where possible
- Review non-value added operations-remove or outsource
- Improve Product Quality!
- Track Customer Quality-Complaints
- Track Supplier Quality
- Track Internal Quality
- Increase Productivity!
- Cross Train Work Staff
- Evaluate employee efficiency
- Show reported labor against actual % efficiency
- Increase Work Flow through cell-Layout improvements
- Modify Cell Layouts-Inventory Staging @ work areas
- Improve the visual state of the plant-Implement World Class 6S!
- Visual-Remove ALL sign painting, replace with professional signage
- Outline location for ALL equipment and Tooling specific to work area
- Permanent place for cleaning supplies-6S Boards
- Remove ALL bottom shelves
- Remove cabinets with doors
- Identify bin sizes to be used in all locations for storing WIP
- Standardize ALL work areas
- Improve Safety
30 Day
- Introduce PACE to staff and all associates
- Align plant goal/objectives to customer needs
- Establish Management presence on the MFG floor
- Introduce World Class 6S Program
- Work Assignments to cells need to be systemic not manual driven
- Allot time to meet all personnel and evaluate plant culture
- Interview Key management personnel
- Interview Key plant personnel
- Review Strengths of the company
- Develop plan to increase
- Review Weakness’ of the company
- Develop action plan to improve
- Establish monthly Communication with plant and staff personnel
- Layout ground rules and expectations for all personnel
- Establish Key indicators by department with responsible Manager
- Establish Manger accountability to personal measurements
- Establish meeting rules-times, days and attendance acceptance
- ALL meetings start ONTIME
- TIMES and DAYS they are held on established
- Specific meeting ATTENDANCE guidelines
- Review Operations financial data
- Include Key Indicators for Manufacturing
- Determine action needed to improve operating margin
- Review budget against results
- Develop action plan in area’s not meeting expectations
- Evaluate working conditions in plant, safety and organization
- Take current state Photos of plant along with After photos
- Determine plant lighting needs and improvement
- Determine needs of floors, paint?, epoxy? Grind surface?
60 Day
- Establish Business Operating System and link it to business goal and objectives
- Review all work instructions currently in place on Mfg Floor for clarity
- Determine accuracy and employee knowledge of them
- Complete value streams on work centers
- Develop a Quality plan tied to customer needs and company goal
- Establish meeting grounds and timeframe for corrective actions
- Establish tracking vehicle for all quality issues, start to closure-8D format
- Including ALL suppliers-COST of Quality
- Count Verification of Material from suppliers
- Develop and Introduce Live Broadcast System to work centers
- Introduce Bar Coding where applicable
- Operator to have Work Assignments at his Work Center
- Establish defined locations for ALL Work Instructions and Quality Alerts
- Establish Kaizen board for communicating changes
- Board will show current state and modified state with documentation and photo’s
- Review overall appearance of plant by location and assign action plan to improve
- Develop a Lean program for plant with Key measurable
- Develop a Kaizen event schedule
- Implement a World Class 6S Program and Train ALL personnel
- 6th S is SAFETY-Establish a safety committee
- Develop a training Matrix for Lean MFG
- Develop a cross training Matrix for plant assembly personnel
- Establish and standardize a visible location for Plant Communication
- Transition culture of company, ALL TEAM members, toward lean initiatives and Lean thinking
90 Day
- Identify staff changes, subtractions or additions
- Review slow moving or dead inventory
- Establish Material Review Board-Red Tag Area
- Develop Purchase Price Index related to yearly cost reductions
- Track Purchase Commodity’s
- Set Annual Goal to Reduce
- Establish Critical Suppliers to Target
- Develop a plant wide cost reduction program
- Improve first impression of plant when walking on the manufacturing floor
- Development and execution of 6S program
- Develop a plant incentive program-REWARD KEY EMPLOYEES
- Establish 6S scorecards with incentive-Gas Cards, Gift Cert, Dinner Cert
- Develop Performance Evaluation
- Merit increases tied to personal performance
- Develop Attendance Structure
- Announce Perfect Attendance applicants
- Train
- Implement
- Execute
- Review Quarterly results with Staff identifying action plans for targets not met
- Standardize all work centers both in appearance and process
- Turn MFG into a visual Plant with signage by location
- Establish company goals and objective handouts to ALL managers for strategic direction
- SUSTAIN ALL 6S EFFORTS to DATE!!!
