施耐德电气公司精益生产体系流程评估标准

G&I/IndustrialDeploymentSchneiderProductionSystemSPSAssessment

Training

(FLV&IC)Icons&meanings Explanation CheckingpointGoodexampleBadexample QuestionIntroduction:3Domains,10Categories,38Lines1–SPSNotion1.

Workinstructionsexistfor:a.Manufacturing.b.Quality.Standardworkhasbeendefinedforeachstation2.WorkinstructionsforSafety(basedonriskanalysis)areposted.(instructionboard/workstation).Safetyinstructioncouldbecombinedwithotherworkinstructions,itmustbeposted(forcriticalmachines/stations)Observewhethertheoperatorrespectsthesafetyinstructions2–SPSBasic3.OperatorsweretrainedusingtheworkinstructionsAskthetrainershowtheyfulfillthetrainingtasksCheckwiththeoperators4.Operatorsunderstandtheworkinstructions:a.Safetyb.Qualityc.ManufacturingThese3kindsofinstructionsshouldbepostedontheworkstationsAsktheoperatorswhethertheyknowthedifferentworkInstructionsdotheyunderstandthemeaningsoftheworkInstructionsPeopleCommitment-SIMProduction

1a-WorkInstructions-P1-Q3–SPSStandard5.WorkinstructionsarevisualWorkinstructionsareeasytobeunderstood,Avoidlongsentence,withfavordrawings/chart,colorfulpictures…Acceptancecriteriasareclearlydefined.6.Workstationinstructionsalsoincludemaintenanceinformationandchangeoverinformation(ifapplicable)Twofilesareconcerned:procedureofvariantchanging&maintenancechecklist(withthetaskandfrequency)TheyshouldbepostedininstructionbookintheU-cell7.WorkInstructionsarerespected(followed)Observethemotionoftheoperatorandcheckwiththeinstructions4–SPSAdvanced8.Thereisastandardprocess,knownbytheoperator,tofollowwhenadefectisdetected(mayincludesignaldevice,empowermenttostoptheline,calltheSupervisor)DecisionmakingprocedureshouldbeavailableforoperatoratcelllevelCheckwithoperatorsPeopleCommitment-SIMProduction

1a-WorkInstructions-P1-QFocuson: WorkInstructionsavailableatworkstation/cell/sectorKeypoints:

5mainWorkInstructions(inorderofpriority)Safety(forcriticalmachine/stations)Quality,ProcessflowchartwithQualitycheckpoint.Operations/LineDrivingPreventiveMaintenance/Maintenance(forcriticalmachine/stations)ChangeOver&Managementinstructions(versatilitychart,5S…)WhyweneedWorkInstructions?TotrainoperatorsTochecktheoperatorsonthemainrulestofollow,especiallySafety&QualityTounderstandtheGlobalProcess(Flow-Chart)WorkInstructionsmustbeKnown&respectedSimpleandVisual:canbeseenattheworkstation,avoidlongsentences,usefavordrawing,easytounderstandandacceptancecriteria'sareclearlydefined.KeepUpdatedAuditinworkshopPeopleCommitment-SIMProduction

1a-WorkInstructions-P1-Q1-SPSNotion 2-SPSBasic 3-SPSStandard 4-SPSAdvanced 5-SPSExpert1.Workinstructionsexistfor:a.Manufacturing.b.Quality2.WorkinstructionsforSafety(basedonriskanalysis)areposted.(instructionboard/workstation).4.Operatorsunderstandtheworkinstructionsa.Safetyb.Qualityc.Manufacturing8.Thereisastandardprocess,knownbytheoperator,tofollowwhenadefectisdetected(mayincludesignaldevice,empowermenttostoptheline,calltheSupervisor)5.Workinstructionsarevisual9.Operatorsareroutinelyparticipatingindeterminationofnewstandardizedworkanddefinitionofworkinstructions10.Workinstructionsare100%visual7.WorkInstructionsarerespected(followed)3.Operatorsweretrainedusingtheworkinstructions11.Workinstructionsarecontinuouslyimproved6.Workstationinstructionsalsoincludemaintenanceinformationandchangeoverinformation(ifapplicable)PeopleCommitment-SIMProduction

1a-WorkInstructions-P1-Q4–SPSAdvanced(continued)9.OperatorsareroutinelyparticipatingindeterminationofnewstandardizedworkanddefinitionofworkinstructionsOperatorsareInvolvedwhenre-thinkingthesystemandgeneratingideasforimprovementAsktheoperators:Dotheyhavesuggestionstoimprovequality,toreducethewaste?Howdotheysubmitthesuggestions?isthereaformalproceduretofollow?visualworkinstructions5–SPSExpert10.Workinstructionsare100%visual

11.WorkinstructionsarecontinuouslyimprovedPeopleCommitment-SIMProduction

1b-Shortintervalproductiontracking-P3-Q

1-SPSNotion 2-SPSBasic 3-SPSStandard 4-SPSAdvanced 5-SPSExpertFocuson: ProductiontrackingKeypoints:

Quality&efficiencytrackedhourlybyoperatorParetoanalysisfordefectsandwastesisroutinelydoneandupdated(daily,weekly,monthly)“5why”isusedtoidentifytherootcauseRecurrenceofdefectsaretrackedandanalyzedActionsareefficientKPI’s:MDR-KE-IE-NEEAuditinworkshop1.ProductionTracking-GoodPartsandDefectsNumbers-isimplementedpershiftbytheoperators3.Productionistrackedhourlybytheoperators(orcoherentdefinedeventcycle)5.ProductiontrackingincludesaRed-Greenbreakdownandthetop3causesofred.6.Processandcomponentdefectsaretrackedasakeyindicator.7.QualitydefectsareanalyzedandCountermeasures(containmentand/orcorrectiveaction)areconductedwithinthecurrentshift8.ComplexissuesareaddressedthroughSix-SigmaorKaizen9.Paretoanalysisofqualityissuesandwasteisroutinelydoneandupdated.10.Atleast80%ofthedifferencebetweenred/greenisexplaineddowntorootcauses.11.Correctiveactionresultsleadtoarecurrenceanalysisofdefects(defecttypesaretrackedandrecordedinalogfile)

4.Atthebeginningofeachshift,thereisareviewwithoperatorsofissuesandobjectivesrelatedto:a)production;b)quality;andc)barriers2Operatorsareawareofcurrentandpotentialprocessandcomponentqualitydefectsrelatedtoeachproductrange1–SPSNotion1.

ProductionTracking-GoodPartsandDefectsNumbers-isimplementedpershiftbytheoperatorsProductiontracking(includequantityandquality)donebyoperatorpershiftCheckatcelllevel2.OperatorsareawareofcurrentandpotentialprocessandcomponentqualitydefectsrelatedtoeachproductrangeOperatorsareawareofqualitydefectsrelatedtoeachproductrangeDefectsarelistedbyQC(ex.Differentcodemeansdifferentdefects)Checkwithoperators2–SPSBasic3.Productionistrackedhourlybytheoperators(orcoherentdefinedeventcycle)Productiontracking(includequantityandquality)donebyoperatorhourlyIfTT>0.5H,theintervaloperatorrecordedshouldequaltoTTChecktheSIMsheetatcelllevel4.Atthebeginningofeachshift,thereisareviewwithoperatorsofissuesandobjectivesrelatedto:a)production;b)quality;andc)barriersObserveintheworkshoptocheck:Isthereameetingwithoperatorsatthebeginningofshift?Whatkindoftopicsreviewedinthismeeting?PeopleCommitment-SIMProduction

1b-Shortintervalproductiontracking-P3-QPeopleCommitment-SIMProduction

1b-Shortintervalproductiontracking-P3-Q3–SPSStandard5.ProductiontrackingincludesaRed-Greenbreakdownandthetop3causesofred.Red-GreenbreakdownshoulddoneaccordingtoSPSTop3causesofredshouldbeanalyzeddaily6.ProcessandcomponentdefectsaretrackedasakeyindicatorFortheprocessdefects,ittrackedasFirstPassRatio,etc.Fornonqualitypart,Scrap,it’scalculatedinNQC.CheckwithlineleaderandQCengineer.7.QualitydefectsareanalyzedandCountermeasures(containmentand/orcorrectiveaction)areconductedwithinthecurrentshiftInformationontheQualityissueincludesthefollowingitems:whathashappened/whatistherootcause/whatisthecountermeasure-containmentand/orcorrectiveaction-/whoisresponsible/whenTheanalysismustbebasedoncomparison-goodpart/badpart,operator1/operator2,day1/day2,-andfactsActioneffectivenessisverifiedbythelineleader/supervisorCheckwiththelineleader/supervisorRed/GreenbreakdownaccordingtoSPSPeopleCommitment-SIMProduction

1b-Shortintervalproductiontracking-P3-Q4–SPSAdvanced8.ComplexissuesareaddressedthroughSix-SigmaorKaizenSix-SigmaisfocusonreducingvariabilitytoreachaperformanceonaprocessKaizenisfocusoneliminatingwasteonthewholeproductflow9.ParetoanalysisofqualityissuesandwasteisroutinelydoneandupdatedParetoanalysisofqualityissuesandwastedoneandupdatedatleastdoneweekly10.Atleast80%ofthedifferencebetweenred/greenisexplaineddowntorootcausesUse“5why”tofindtherootcausesPeopleCommitment-SIMProduction

1b-Shortintervalproductiontracking-P3-Q5–SPSExpert

11.Correctiveactionresultsleadtoanrecurrenceanalysisofdefects(defecttypesaretrackedandrecordedinalogfile)Defectsandnonconformitiesaretrackedandrecordedbydefecttypeinalogfile.Thisistheonlywaytomakesurethehavebeeneradicatedbythecorrectiveactions.ThislogfilemustbedisplayedontheinformationboardoftheproductioncellRecurrenceofdefect2!PeopleCommitment-SIMProduction

1c-SIMProductionimplementation-P4,P10

1-SPSNotion 2-SPSBasic 3-SPSStandard 4-SPSAdvanced 5-SPSExpertFocuson: SIMProductionimplementedandrespectedtheplanteventcycle.Keypoints:

OperatorsareinvolvedinSIMProduction(beginning/endofshift)ObjectivesDefinitionResults/BarrierLog&SuggestionsystemmanagementSafety&5SManagementSupportfunctionsareinvolvedinSIMProductionResultsAnalysis/IndicatorsReviewBarrierLogManagementActionPlanManagement/EscalationsystemAuditinworkshopAttendthedailySIMmeeting1.SIMProductionconcepts(SPSModel)arepartiallyimplemented2.PlantEventCycle(frequency,contributors,deliverables)isknownbyeveryoneinproduction3.SIMProductionisled(requiredbyandparticipatedin)bythePlantManager4.Cell/ProductSectorshortintervalcyclesandfrequencyarerespectedaccordingtoSPS5.Themanagerandhisteamrespectthefrequencyanddurationoftheeventcycle6.Supportfunction'smembers(Methods,Materials,Logistics,Maintenance,Quality,Engineering…)participateinSIMProductionmeetings7.InternalKPIsparticulartotheproductorprocesshavebeenestablishedandaretracked.8.Theshiftsupervisormanagestheactionplansandpoststhem9.Evidenceofdynamicmanagementoftheactionplans:a)followedup,b)ontime,c)evidenceofsuccess.10.HumanresourcesfacilitateandAssesstheSIMProduction11.Eachmanufacturingsectorconsistentlyreachone’sKPI’sobjectives.12.InternalKPIsshowsustainedimprovementovera12monthsperiodKPI’s:Output:Realized-ForecastedSafety+5SQuality:ServiceLevel-MDREfficiency:KE/IE–NEE/OEEBarrierLog+ActionPlanPeopleCommitment-SIMProduction

1c-SIMProductionimplementation-P4,P101–SPSNotion

1.

SIMProductionconcepts(SPSModel)arepartiallyimplementedThereareregularSIMmeetingsinproductionCheckwithoperators,lineleaders,productionmanager

2.PlantEventCycle(frequency,contributors,deliverables)isknownbyeveryoneinproductionPlanteventcycleareestablishedincludefrequency,contributors,deliverables

SPSSIMeventCycles2–SPSBasic3.SIMProductionisled(requiredbyandparticipatedin)bythePlantManagerAskplantmanagerwhetherheknowtheplanteventcycle,doeshe/sheattendtheSIMdailymeeting(onceperweek)Checkwithproductionmanager4.Cell/ProductSectorshortintervalcyclesandfrequencyarerespectedaccordingtoSPSThereareshiftly,daily,weeklymeetingaccordingtoSPSCheckwithoperators,lineleaders/supervisors,productionmanager5.ThemanagerandhisteamrespectthefrequencyanddurationoftheeventcycleSIMmeetingatfixedtimewiththefixeddurationCheckwithlineleaders/supervisors,andobservethedailymeeting.3–SPSStandard6.Supportfunction'smembers(Methods,Materials,Logistics,Maintenance,Quality,,Engineering…)participateinSIMProductionmeetingsObservethedailymeetingandcheckwiththeparticipates.7.InternalKPIsparticulartotheproductorprocesshavebeenestablishedandaretrackedKPIsincludeoutput,safety,5S,OTDM,MDR,KE/IE,NEE/OEE,shouldbereviewedinthedailySIMmeetingObservethedailymeetingtocheckwhethertheKPIsbetrackedPeopleCommitment-SIMProduction

1c-SIMProductionimplementation-P4,P10PeopleCommitment-SIMProduction

1c-SIMProductionimplementation-P4,P104–SPSAdvanced8.TheshiftsupervisormanagestheactionplansandpoststhemActionplansshouldbefollowedandpostedontheSIMboard.9.Evidenceofdynamicmanagementoftheactionplans:a)followedup,b)ontime,c)evidenceofsuccessChecktheactionfollow-upfiletoseetheevidence10.HumanresourcesfacilitateandAssesstheSIMProductionHRneedtobeinvolvedinSIMproduction,Attendthedailymeetingfrequently,Organizeregularaudit,…5–SPSExpert11.Eachmanufacturingsectorconsistentlyreachone’sKPI’sobjectivesCheckKPIs(output,safety,5S,OTDM,MDR,KE/IE,NEE/OEE)reporttoseetheresult12.InternalKPIsshowsustainedimprovementovera12monthsperiodCheckthe12monthstrendPeopleCommitment-SIMSupportFunctions

2a-SIMsupportfunctions-P5,P101-SPSNotion 2-SPSBasic 3-SPSStandard 4-SPSAdvanced 5-SPSExpertFocuson:

SIMsupportfunctionimplementedandrespectedtheplanteventcycle.Auditin2-3supportfunction1.SIMProductionconcepts(SPSModel)arepartiallyimplemented2.PlantEventCycle(frequency,contributors,deliverables)isknownbyeveryoneinproduction3.SIMProductionisled(requiredbyandparticipatedin)bythePlantManager4.Cell/ProductSectorshortintervalcyclesandfrequencyarerespectedaccordingtoSPS5.Themanagerandhisteamrespectthefrequencyanddurationoftheeventcycle6.Supportfunction'smembers(Methods,Materials,Logistics,Maintenance,Quality,Engineering…)participateinSIMProductionmeetings7.InternalKPIsparticulartotheproductorprocesshavebeenestablishedandaretracked.8.Theshiftsupervisormanagestheactionplansandpoststhem9.Evidenceofdynamicmanagementoftheactionplans:a)followedup,b)ontime,c)evidenceofsuccess.10.HumanresourcesfacilitateandAssesstheSIMProduction11.Eachmanufacturingsectorconsistentlyreachone’sKPI’sobjectives.12.InternalKPIsshowsustainedimprovementovera12monthsperiodKPI’s:%Tasksdone/Tasksplanned%TasksintimeDiarywithred/greenKeypoints:

EventcyclearedefinedandrespectedTheremustbeaindividualmeetingbetweenmanagerandhisstaff(1to1)DiaryisusedtomanageworkloadWorkloadisplanedandmeasuredWorkloadisanalyzed:red/green,realized/forecastedSupportFunctionsarefocusedonProduction&CostumerServiceGlobalActionPlanisdefined,BarrierLogisupdatedinSIMPrioritiesaredefinedandareconsistentintheagendaofallsupportfunctionsPeopleCommitment-SIMSupportFunctions

2a-SIMsupportfunctions-P5,P101–SPSNotion1.SIMSupportFunctionconcepts(SPSModel)areknownPlantmanagementteamreceivedtheSIMtraining2.PlantEventCycle(frequency,contributors,deliverables)isknownbyallsupportfunctionsPlanteventcycleareestablishedincludefrequency,contributors,deliverables.Checkwithsomesectormanagerandstaffs2–SPSBasic3.SIMSupportFunctionsisled(requiredandparticipatedin)bytheplantManagerAskplantmanagerwhetherheknowtheplanteventcycle,Aretherescheduled1to1meetingbetweenplantmangerandfunctionmanagersweeklyIsthereaweeklycoordinationmeetingwithallsupportmanagerCheckwithfunctionmanagers4.ThemanagerandhisteamrespectthefrequencyanddurationoftheeventcycleSIMmeetingholdatfixedtime,withfixeddurationCheckwithsupportengineers5.Themanagerorganizesaweeklycontactwithhisstaff(1to1)Thereisaweekly1to1meetingbetweenfunctionmanagerandhisstaffstoreviewactionplan,workload,priority…CheckwithstaffsPeopleCommitment-SIMSupportFunctions

2a-SIMsupportfunctions-P5,P103–SPSStandard6.Staffindividual’sdiaryisusedasaschedulingtoolCheckseveralindividualdiariestoseethesituation7.Aglobalproduct-processactionplanisavailableandupdatedChecktheactionfollow-upfile(atplantlevel)toseewhetheritisreviewedandupdated8.SIMSPSmodelisfullyimplementedFunctioneventcycleexitandrespectSPSThere’s1to1meetingbetweenmanagerandhisdirectreportsDiariesareusedtomanageworkloadSupportfunctionarefocusedonproduction&costumerservice

SPSSIMeventCyclesPeopleCommitment-SIMSupportFunctions

2a-SIMsupportfunctions-P5,P104–SPSAdvanced9.Diaryplanningintervalsare<2hoursblocksCheckseveralindividualdiariestoseetheinterval10.TasksplannedinthediariesaccordingtotheParetoAnalysisofissues/barriersidentifiedproductionTasks&ActionplanscomefromParetoAnalysisofissues/barriers

inproductionSIMCheckstaffdiariesofsupportfunctionwiththeactionfollow-upfileonproductionSIMboardtowhethertheyarematched11.HumanresourcesfacilitateandAssesstheSIMSupportFunctionsHRmustfacilitateandassessthesupportfunctionSIM,tosetupKPIsforallfunctionDept,tomeasurestaffworkload,toorganizeregularreview/audit,…5–SPSExpert12.ManufacturingKPI'sareincontinuousimprovementCheckKPIsreporttoseetheresultPeopleCommitment-SIMSupportFunctions

2b-SIMSupportfunctionsEfficiency-P6

1-SPSNotion 2-SPSBasic 3-SPSStandard 4-SPSAdvanced 5-SPSExpertFocuson: Staffworkloadmanagement&supportfunctionefficiency.Keypoints:

Prioritiesareknownbyeachstaffmember-bothfactoryprioritiesandpersonalprioritiesPrioritiesaretakenintoaccountandevidenceexistsinthe“to-do”listsanddiariesResourcesareadapted:resourcesareappliedtothehighestpriorityactivitiesActivitiesoractions:doestheplantverifyandfollow-upthattheresultsaresustained?KPI’s:%Tasksdone/Tasksplanned%TasksintimeAudit2-3supportfunction1.Globalteamworkloadisassessed.(eg:AnnualHumanResourceRevieworBusinessPlanCycle)2.Individualworkloadisassessed(todolist)3.SupportFunctionscoreskillsaredefinedandformalized(updatedonceayear)4.Numberoftaskscarriedoutperpersonperweekisscheduledandtracked(RatioImplemented/Scheduled)5.Workloadandresourcesarewellbalancedaccordingtotheobjectives6.SupportfunctionshavedefinedtheirownKPI's;theyaretracked&analyzed7.SupportFunctionKPI'sareincontinuousimprovementPeopleCommitment-SIMSupportFunctions

2b-SIMSupportfunctionsEfficiency-P61–SPSNotion1.Globalteamworkloadisassessed.(eg:AnnualHumanResourceRevieworBusinessPlanCycle)ThisglobalworkloadassessmentisthebaseofDeptheadcountrequirement,Itshouldbereviewedonceayearorbaseonbusinessplancycle.CheckwiththeDeptmanager2–SPSBasic2.Individualworkloadisassessed(todolist)Usethesometoolstoassesstheindividualworkload(e.g.to-do-list).Thecontentsofthefileshouldincludeworkload,priorities,duedate,planedratio…Checkwithdept.managerandstaff3.SupportFunctionscoreskillsaredefinedandformalized(reviewedonceayear)Makethered/greenactivitiesselfanalysisforeachnon-DVCemployeeMakeacompetency(skills&knowledge)assessmentforeachemployeeClearlydefinetheJDforeachstaff,andtheJDshouldbereviewedonceayear.Checkwithdept.managerandstaffPeopleCommitment-SIMSupportFunctions

2b-SIMSupportfunctionsEfficiency-P63–SPSStandard4.Numberoftaskscarriedoutperpersonperweekisscheduledandtracked(RatioImplemented/Scheduled)Auditseveralindividualdotolistanddiary.Checktheratioofimplemented/scheduled5.WorkloadandresourcesarewellbalancedaccordingtotheobjectivesMeasureandbalancetheindividualworkloadResourceareappliedtothehighpriorityactivitiesaccordingtotheobjectives4–SPSAdvanced6.SupportfunctionshavedefinedtheirownKPI's;theyaretracked&analyzedKPIsclearlydefinedforeachdepartment,KPIsshouldbetracked,analyzedandtakeactionstoimproved.ObjectivesandrealdataofKPIsshouldbepostedineachdepartment5–SPSExpert7.SupportFunctionKPI'sareincontinuousimprovementCheckKPIsreporttoseetheresultPeopleCommitment-SIMSupportFunctions

2c-SuggestionSystem-P7

1-SPSNotion 2-SPSBasic 3-SPSStandard 4-SPSAdvanced 5-SPSExpertFocuson: DashboardforSuggestionsKeypoints:

Suggestionsystemisencouraged/managedinSIMproduction(teamleader–operatorsshiftlymeetingSuggestionsystemisformalized:Issuedate,acceptorrefuseActionpilotImplementationdateInformationiscurrentandupdatedfrequentlytomatchtheeventcycleofSIMproductioninformationisnot“old”,formsdonot“wait”tofilledout.KPI’s:NumberofsuggestionspermonthMeantimetoreply/toimplement1.Thereisasystemorprocesstorecordemployeesuggestions2.Projectspecificsuggestionsystemsareutilizedtoformalizeemployeefeedback3.Suggestionsarevisualandafeedbackisgivenwithin30days.4.Supervisorsworkwithemployeestorefinesuggestions.5.Acommitteeevaluatessuggestions.6.Suggestionsarevisualandafeedbackisgivenwithin2weeks7.Suggestionsarevisualandafeedbackisgivenwithin1week.8.Thecontentofthesuggestionsbecomesmoreimportantthantheqtyposted:KPI’stracked.9.Thereisanincentivesysteminplaceforsuggestions.10.Additionalrewardsexistfor"outstanding“suggestions.11.KPI'sshowcontinuousimprovementofsuggestionsystem1–SPSNotion1.

Thereisasystemorprocesstorecordemployeesuggestions.Thereisasimplesystem/processtorecordsuggestionsAskHRmanagertodotheroughlyintroductionoftheplantsuggestionsystem2–SPSBasic2.Projectspecificsuggestionsystemsareutilizedtoformalizeemployeefeedback

ThereisaformalproceduretodefinehowthesuggestionsystemworksSuggestionscouldbedevelopedasactionplans,projects…3.Suggestionsarevisualandafeedbackisgivenwithin30daysSuggestionsheetsarepostedontheboardtoshowthesituationsandprogress.Checktheissuedateandfeedbackdatetoseewhetherthedurationis<30days3–SPSStandard4.SupervisorsworkwithemployeestorefinesuggestionsSupervisorcollect,refineanddistributethesuggestionsonceaday5.AcommitteeevaluatessuggestionsEveryday,atafixedtime,thedesignatedcontactpersonineachdepartmentexaminesthenewsuggestionsandallocatesthemtohisdepartment(onecoordinatordesignatedpersheet).PeopleCommitment-SIMSupportFunctions

2c-SuggestionSystem-P73–SPSStandard(continued)6.Suggestionsarevisualandafeedbackisgivenwithin2weeksThecoordinatormustfacetofacediscusseachnewsheetwiththerequestertowellunderstandtheproblem,theproposal,andsoon.Ifthesuggestionisaccepted,thecoordinatorandtherequesterwilldecideontheappropriateactiontobeundertakenOnceanactionisundertaken,thecoordinatorandtherequestershouldconfirmitbysigningonthesheetCheckwithpoint34–SPSAdvanced7.Suggestionsarevisualandafeedbackisgivenwithin1weekCheckwithpoint38.

Thecontentofthesuggestionsbecomesmoreimportantthantheqtyposted:KPI’strackedImprovethesuggestionsfromquantitytoquality.KPIstrackedwiththetargets,includenumberofsuggestionissued,waitingtimeforfeedback,actionundertakenrate,actionontimeimplementedrate…9.ThereisaincentivesysteminplaceforsuggestionsRewardsystemforsuggestionsisexistedintheplantCheckwiththeoperatorsandstaffwhethertheyknowthisrewardsystemPeopleCommitment-SIMSupportFunctions

2c-SuggestionSystem-P75–SPSExpert10.Additionalrewardsexistfor"outstanding“suggestionsCleardefinitionoftheoutstandingsuggestionisexistedTheresultofthesuggestionshouldbemeasurable.(ex.lowcost,highsavings…)Checkwiththeoperatorsandstaffwhethertheyknowthisadditionalrewards11.KPI'sshowcontinuousimprovementofsuggestionsystemCheckKPIsreporttoseetheresultPeopleCommitment-SIMSupportFunctions

2c-SuggestionSystem-P7PeopleCommitment-ContinuousImprovement

3a-Operatorflexibility-P2

1-SPSNotion 2-SPSBasic 3-SPSStandard 4-SPSAdvanced 5-SPSExpertFocuson:Matchingdemandandresources.Keypoints:

NumberofoperatorsinacellvariesaccordingtoworkloaddemandSamelevelofKEwithminimumandmaximumofoperators(KE>80%)Productionclearlyunderstandstheirdemand-includingdistributioncentershortagesand/orcustomerexpeditesandadjuststheirscheduleandstaffingtorespondKPI’s:OperatorEfficiencyKE–SUR(auto)Auditinworkshopminimumproductionratemaximumproductionrate1.Conceptofoperatorflexibilityandteamworkspiritaccepted2.Operatorsaretrainedtooperateseveralstations/machineswithinaline/cell3.Flexibilityand/ormultimachinemanningispartiallyimplemented(>30%ofthesector)9.KEremainshigherthan80%withnumberofoperatorsvaryingwithdemand.8.KPI’s(KE&/orSUR)showa6monthscontinuousimprovement4.Flexibilityand/ormultimachinemanningisimplemented(>80%ofthesector)5.Organizationandbalanceoftheline/cellminimizewaitingtimeand/ormoves6.KE(manual)andSUR(auto)aretrackedandanalyzed(Pareto)7.Resourceflexibilitydrivenbycustomerdemand:balancingdoneinsideeachshift10.K