Error proofing Evidence Gathering
Questions to ask people in the plant to aid in your assessment...
? Have employees been trained in the process of error proofing?
? Wherever defects occur, do problem-solving teams identify permanent corrective actions that include error proofing?
? Have error-proofing devices been developed and installed at each workstation? ? Is there a system in place to verify that error proofing is working?
? Can all defects be detected before being passed on to the next process?
? Are employees empowered to stop the process when a defect or abnormal condition occurs? ? Are errors detected before the parts are processed at the workstation? ? Has error proofing been designed into the product wherever appropriate? ? Can operators bypass error-proofing devices?
? What is the trend in key indicators such as scrap, rework and first run capability? Enablers
Disablers Evidence of Best Practices
Quick Changeover
Definition : Quick changeover is a state and process of achieving extremely fast setup times for equipment and processes. The goal is to change over parts within the customer?s cycle (takt) time. This may be based upon SMED (single minute exchange of dies) or similar philosophy e.g. separating external from internal work within a setup. Instructions: Fill in the number of “quarters” for each circle that correspond to the level observed in the plant. Use the questions on the back of this sheet to aid in evidence gathering. Divide the number of quarters shaded by the total number of quarters to determine percent implementation.
Level
1
Measurable % Evident Changeovers are scheduled and necessary employees have the schedule.
1243 2
Management understands and accepts quick set-up as an important technique in implementing lean systems; quick changeover teams have received formal quick set-up reduction training.
Set-up activities have been videotaped to allow for detailed analysis. Kaizens have been focused on reducing set-up time.
3
4 Quick set-up time (internal and external) is tracked visibly in the area where the setup is done.
5
New set-up procedures have been standardized, documented and posted; all affected
employees have been re-trained; production planning uses the reduced changeover times in planning.
No changeover operation takes more than three minutes and all are done within the cycle time (takt time).
6
Quick Changeover Assessment = Filled Quarters / Total Quarters ____/_24_ = _____ %
Key: 0: 1: 2:
0% - Not found anywhere
3: 4: 75% - Very typical, some exceptions 100% - Everywhere in plant, no exceptions 25% - Only seen in some areas 50% - Commonly found but not in the majority of cases
Quick Changeover Evidence Gathering
Questions to ask people in the plant to aid in your assessment...
? Have employees been trained in the process of quick changeover?
? Do employees understand SMED (single minute exchange of dies) philosophy? ? How often are changeovers performed? Weekly? Daily? Hourly? ? Have kaizens focused on decreasing changeover time? ? Is there a visual signal system for changeovers? ? How are changeovers scheduled?
? Is there a team assigned to reducing set-up times?
? Do employees understand the need for reduced set-up times? ? Is there a system in place to track changeover times? Enablers
Disablers Evidence of Best Practices
Total Productive Maintenance
Definition : TPM strives to be based on high worker involvement and responsive support functions. TPM seeks to prevent all failures and process operation disruption. The goal of TPM is a stable production environment where machine failures do not affect production. Planned versus unplanned downtime is a good way to measure the effectiveness of TPM. Instructions: Fill in the number of “quarters” for each circle that correspond to the level observed in the plant. Use the questions on the back of this sheet to aid in evidence gathering. Divide the number of quarters shaded by the total number of quarters to determine percent implementation.
Level
1
Measurable % Evident Machines are guarded for safety and locked out immediately when broken. Maintenance department is responsible for all maintenance activities.
Accurate and visible maintenance histories are kept up to date and posted near all equipment.
1243 2
3
Preventive maintenance is practiced - key employees have been trained in the basics of TPM; major and minor accidents rarely occur. Operators fill out maintenance check sheets.
Preventive maintenance responsibilities are well defined. Operators are doing daily tasks like checking, oiling and cleaning machines. Maintenance team is evolving from preventive to predictive abilities.
Plant-wide maintenance activities are consistently practiced - available productive time for all equipment is tracked and increasing. Machine breakdowns or accidents rarely occur.
4
5
TPM Assessment = Filled Quarters / Total Quarters ____/_20_ = _____ %
Key: 0: 1: 2:
0% - Not found anywhere
3: 4: 75% - Very typical, some exceptions 100% - Everywhere in plant, no exceptions 25% - Only seen in some areas 50% - Commonly found but not in the majority of cases
Total Productive Maintenance Evidence Gathering
Questions to ask people in the plant to aid in your assessment...
? Are accurate and visible maintenance histories visible on or near each piece of equipment? ? Are machines guarded for safety and locked out immediately when not in use. ? Is maintenance reactive, preventive or predictive? ? Have all key employees been trained in TPM?
? Is performance tracked for each piece of equipment? ? How common are equipment breakdowns?
? Is scheduled vs. unscheduled machine downtime tracked?
? Is there evidence of permanent corrective actions when breakdowns occur? ? Is there evidence that maintenance always occurs as scheduled?
? Are there daily check sheets (lubrication, inspection, calibration, cleaning, etc) for operators to sign off present and up-to-date on each machine? ? Are standards set for each maintenance task?
? Do audits occur to verify the effectiveness of maintenance standards? ? Is equipment inspected prior to the start of each shift?
? Where audits identify discrepancies, are corrective actions spelled out and completed? Enablers
Disablers Evidence of Best Practices
Material Control/Kanban