【正文】 Develop data request form ? Explain data requirements and format for data summary to potential client ? Recognize potential data limitations Write cover letter for data request ? Provide detailed instructions, definition s, etc. for data request ? Clearly spell out data definitions to minimize mistakes in data collection Kick off the process with target pany managers ? Introduce yourself and clarify the details of the request (timing, content, process) ? Recognize and ap preciate resource limitations of client Identify key contacts ? Have at least one person in finance and one in operations that you can contact directly ? Recognize the primary contact might not have first hand access to all the data Follow up Get benchmarking data* ? Ensure data has been collected prior to the actual diagnostic kickoff ? Begin forming a cooperative relationship with client ? Benchmark client to industry ? Lead time for Ramp。I * See analyses example pack for details on benchmarking CLE_ZXG779_Apr0302_1WkDiagnostic_v1 7 DETAILED DATA REQUEST ? Sales revenue – Dollars (by product) ? Top customers ? Major suppliers ? Number of units produced annually ? Number of parts produced ? Overall inventory turns ? Raw material – Dollars ? WIP – Dollars ? Finished goods – Dollars ? Copy of plant layout ? Floor space ? Organizational chart ? Annual cost per FTE ? Number of shifts/day ? Work hours/shift ? Overall factory utilization and capacity ? List of current improvement initiatives ? Turnover – Percent ? Absenteeism – Percent Inventory Plantspecific data General People ? Break down of COGS – Material cost – Dollars – Direct labor cost – Dollars – Overhead – Dollars ? Variable (indirect labor, etc.) ? Fixed (depreciation, etc.) ? Copies of ine statement and balance sheet ? Overtime – Percent ? Typical productivity improvement for last 35 years – Percent ? Delivered customer PPM ? Internal PPM (or firstpass yield) ? Scrap per year – Percent and dollars ? Rework – Percent and dollars ? Warranty cost – Percent of sales ? Ontime delivery – Percent ? Customer lead time (quoted) – Days ? Premium freight – Dollars ? Manufacturing lead time – Days ? Number/type of machines ? Average setup times – Minutes ? Average down time – Percent Quality Delivery Cost Equipment NOT EXHAUSTIVE CLE_ZXG779_Apr0302_1WkDiagnostic_v1 8 AGREE ON CLIENT RESOURCE REQUIREMENTS Team structure Role Leadership team ? VPoperations ? Plant manager ? McKinsey leadership Core team ? McKinsey EM and associates ? 100% dedicated client resources –Manufacturing manager who is “rising star” –Supervisor from model area Support team ? Representatives from many functions (~20% dedicated) –Finance –Materials –Scheduling –Process engineers –Maintenance ? Direct and support the diagnostic ? Lead the diagnostic and report findings to leadership team ? Client resources assist in: –Identifying and ensuring access to the right people –Transferring knowledge about the facility ? Offer insight and data to guide the core team EXAMPLE CLE_ZXG779_Apr0302_1WkDiagnostic_v1 9 FINALIZE WORK PLAN . . End products Theme Monday Tuesday Wednesday Thursday Friday ? Kick off meeting with management ? Introductory plant tour ? Review baseline data ? Finalize model area ? Begin to map current material and information flows ? Basic understanding of operations and data collected ? Continue mapping material and information flows ? Begin demand pattern analysis ? Begin to collect operational data ? Collect operational data ? Identify root causes ? Hold interviews with several support functions – Maintenance – Scheduling – Etc. ? Current state well understood ? Develop future state material and information flows ? Design improved layout ? Develop future operating metrics ? Future state vision defined ? Quantify financial benefits ? Assess anizational capability for change ? Assess main impediments to change ? Determine highlevel implementation plan ? Financial impact ? Barriers to change ? Implementation plan ? Synthesize findings ? Prepare presentation for final review ? Diagnostic presentation EXAMPLE Verify baseline data and get acquainted with the facility Current state data collection Plant layout and vision Financial quantification and future state Implementation planning CLE_ZXG779_Apr0302_1WkDiagnostic_v1 10 DIAGNOSTIC APPROACH Activities Timing Main end products ? Determine approach and objectives ? Launch data request ? Determine resource requirements ? Finalize work plan ? 13 days ? Initial data request ? Clearly defined team and work plan ? Hold kickoff meeting ? Complete business needs assessment ? Select model area/ products ? Determine cost structure ? Map current material and information flows ? Complete detailed analyses ? Assess physical and anizational capability ? 12 days ? Current state physical and anizational analysis ? Operational metrics ? Develop future state material and information flows ? Create guidelines for future anizational structure ? Develop targets for oper