【文章內(nèi)容簡介】 12 SUGGESTED PILOT AREA IMPLEMENTATION APPROACH XX weeks Refine Current state assessment – target state design ? Business need validation ? Product and process profiling ? Problem identification ? Current state analysis ? Target state vision ? Confirm opportunity ? Proposed tactical implementation plan ? Focus on major capacity losses ? Stabilization of equipment ? Process consistency and instation quality ? Standardized labor activity and processes ? Definition of core production system ? Performance metrics and dialog ? Controlled inventory ? Line amp。 cell type layout ? Changeover time reduction activities ? Controlled flow patterns to minimize losses due to – Down time – Speed loss – Quality loss ? Consistency of production pace and output ? Demanddriven pull production schedule ? Direct feedback with upstream/ downstream customer linkages ? Improved munication with support departments (maintenance, scheduling, etc.) ? Auditing process ? Plan for sustaining support ? Ongoing 39。checkup39。 support Maintain Stabilize Flow Pull Next area Phase 1: confirm opportunity Phase 2: capture opportunity for model line Phase 3: Team of lean experts rolls out to next area XX XX weeks 14 MODEL AREA APPROACH ? Develop practical systems to countermeasure waste creation ? Build momentum for lean thinking ? Define current work practices and procedures ? Define material, information, and people flows ? Quantify baseline operational metrics ? Identify all forms of waste and understand how system drives waste Check/act Plan Do Lean diagnostic Make changes and test Refine 2 weeks 5 weeks 1 week ? Change layout to ensure sustainability and capturability ? Evaluate effectiveness of changes made ? Learn by doing and build internal experience Tools used ? 5S ? Production board ? Poka yoke ? Kaizen ? Standard work ? Kanban ? Test effectiveness of systems and countermeasure where applicable ? Evaluate metrics and determine areas for further improvement ? Create continuous improvement culture mentality Tools used ? Performance Management ? Improvement events Tools used ? Spaghetti diagram ? Value stream map ? Waste . sheets ? 5 why analysis Develop tools, techniques, and measurements Progress Reviews Implementation overview (week 5) Present Results (End of week 8) Finalize Plan (week 2) Source: McKinsey Manufacturing practice Multiple areas 16 weeks? 15 PSDC ENGAGEMENT APPROACH ? Ensure understanding ? Select model line ? Create infrastructure ? Clientspecific Source: PSDC . model ? Clearly define business unit: operations strategic linkage ? Clear operational priorities, ., quality, capacity ? Specific current: target state picture ? Detailed tactical implementation plan ? Reduce major capacity losses ? Stabilize equipment reliability ? Process consistency and instation quality ? Standardized labor activity and processes ? Define core production system ? Performance metrics and dialog ? Controlled inventory ? Redesign flow patterns to minimize – Travel – Wait time – Inventory ? Production pace or takt time ? Reduce lot sizes ? Demanddriven pull production schedule ? Direct downstream customer linkages ? Audit process ? Create sustaining support plan 16 weeks ? weeks Prepare Current state assessment – target state design Stabilize Maintain Pull Flow Sustaining support 16 SUGGESTED PLAN FOR STABILIZATION PHASE Activity Sauce and salad dressing areas Kick off ? Dedicate resources ? Lean awareness training ? Determine metrics, plans amp。 review process ? Communicate to business OEE improvement ? Pilot implementation (., ultrakan) – C/O workshop online – Downtime problem solving – Startup loss elimination – Visual control ? Roll out to other areas ? 5S and basic maintenance Configuration changes ? Identify formula location changes ? Minor equipment moves ? Investigate warehouse space saving, optimal totes, production pace Performance management ? Start data collection ? Implement scheduling board ? Implement hourly boards and reviews ? Monitor policy deployment Time (weeks) 0 2 4 6 8 10 12 14 16 Major workstream Ongoing support PRELIMINARY 17 Current state assessment Target State design Stabilize Flow Pull Ongoing CI Objectives ? Clearly define business unit: operations strategic linkage ? Clear operational priorities – ., quality, capacity ? Specific current: target state picture ? Detailed Tactical Implementation Plan ? Reduce major capacity losses ? Stabilize equipment reliability ? Process consistency and instation quantity ? Standardized labor activity process ? Core production system ? Performance metrics and dialog ? Controlled inventory ? Redesign flow patterns to minimize – Travel – Wait time – Inventory ? Production pace or takt time ? Reduce lot sizes ? Demanddriven pull production schedule ? Direct downstream customer linkages ? Ongoing Policy Deployment ? Kaizen teams ? Employee involvement ? HR and training systems Time 3 4 Weeks 4 9 Months Ongoing PILOT AREA PHASES 18 PILOT PHASE APPROACH Pilot phase Key levers Core activities Example tools ? Labor availability ?Machine uptime ?Material availability ?Quality ?Maintenance