example of tpm in office europe

8/13/2019 Example of TPM in Office Europe

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1EC

ngineeringentre Unilever

Home and Personal Care - Europe

TPM in Administration

Charles Johnston

KTCS

in conjunction with the

HPCE Engineering Centre


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WHY HAVE ADMINISTRATIONWHY HAVE ADMINISTRATION

Administration is used to

controlcontrol

the systems of a business

every action should

add valueadd value

to the business


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The Supply Chain Business Process

InitialProductionProcess

ExternalSuppliers

Company Infrastructure

Inbound Logistics Manufacturing Service

Sales & Marketing

FinalProductionProcess

Transport/Distribution

ReceiptingWarehouseOperations

Workin

Progress

OrderPlanning &Scheduling

Customer Service Process

TransportDistribution

CustomerReceipt

CustomerHandling

ShelfReplenishing

Consumer

Input /Complaints

Inventory

WarehouseOperations

Customer

Input /Complaints

HPCE

QualitySystem

CustomerOrder

OrderProcessing

InnovationProcess

ImproveCurrent

SC System

OrderProcessing

PurchasingInternal

Processing

Sales/Purchasing Process

SupplierDespatch

Inventory

Customer Inventory Control System

RequirementsOut

SuppliesIn

OutboundLogistics

Physical Movement

Information Flow


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The Product Introduction Process

(Background)

Innovation Technology

AcquisitionCapabilityAcquisition

ProjectManagement

(Foreground)

ConceptDevelopment

ProductDefinition

ConfigurationManagement

ProductLaunch

ProcessDesign

ProcessTest

ProductDesign

ProductTest

Prototyping

ProcessImplementation

MarketingRequirement

Definition

Supply ChainProcess

Innovation: TIME is important?


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Why have this pillar?Why have this pillar?

LossesLosses

LossesLosses

Identify LossesIdentify Losses

in Administrationin Administration

EliminateEliminate

Speed up response to

business demands


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How does this relate to the TPM Pil lars

Focuse

dimprovem

ent

Qu

alitymaintenance

Early

management

(MPd

esign,InitialFlowCnt'l)

Trainingforoperation&

maintenanceskills

Auto

nomousm

aintenance

Focusedimpro

vement

Effectivemai

ntenance

TPM

intheAdministration

Safety,hygiene

and

environmental

activities

The Use of Human Wisdom

TPM

intheAdministration


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ECngineeringentre Unilever


Office TPM Introduction

Areas of Office TPM

Kaizen

5's

Safety

Visual Management

Development of People

Vision

Administrat ion TPM


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Office TPM Introduction

Areas of Office TPM

KAIZEN- Identify your Loss- Measure- Target Set- Analyses- PDCA

5's

- Set Standards- Sort Out- Set Limits

- Shine- Stick to It Safety- Apply 5's- Theme of the

Month- Risk Assessment- DupontAudit

Visual Management- Controlled Environment

- Focused Communication- Safety Working- Public Relations

-

Development of People- Clearer Roles- Skill Enhancement

Autonomous Working

Vision- Your contributionto the Business

- Your objectives- Your image of the

perfect office

Administrat ion TPM


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RoadRoad--Map to TPM within AdministrationMap to TPM within Administration

2. KPIs and Loss Identification

3. Problem Kaizen - measures

4. Standardisation

5. AutonomousManagement of

Activities

1. Initial Clean -up

LOSS


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RoadRoad--Map to TPM within AdministrationMap to TPM within Administration

2. Loss Identification

3. Problem Kaizen

measures

4. Standardisation

5. Autonomous Management of Activities

1. Initial Clean -up

D Tid


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Drawer Tidy


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C t Vi i


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Create a Vision

What is the Perfect Office?

Loss Identification


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Loss Identification

Process to identify losses

Losses recorded and measured

Choose

Kaizen

Identify and

prioritiselosses

Priorities-

Department

& Business

Office

TPM

Define

Losses

Measure

Losses

Too much

paper, complex

ISO procedures.

Long Document

Retrieval time

Physical

Layout

B

Internal

Process

A

ISO Procedures EC Office

904 Breakdown of Areas - "Average Month"

0%

5%

10%

15%

20%

25%

30%

35%

40%

Ops Mtg QA Procedures TPM IT Downtime MP Workshop

Support

Others

% of

904 Total

Are these losses ?

Loss Areas of 904

Responsible Person: R. Johnston &M. Fairhurst

Last Update: Oct-2000

Next Update: Dec-2000

DMSRef:OEE.XLS

Link to Loss Tree Process

Losses


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Losses

PROBLEMS

Current PRS Files stored in personal cupboards

Documentation not stored centrally

Library too far away for easy access

Poor communication between teams

Disturbance from central aisle

User unfriendly environment

Losses defined & reviewed

Kaizen selected

Problems identified for analysis

Librar

y

Electronic

/personaldrivePe

rson

al

Cupbo

ards

Nostructure

Donttalk

toeachother!

Information not

shared

Kaizen is based on developing and using the

creativity and problem solving abilities of all

employees to continuously improve quality

while lowerin cost and reducin lead times.

Measure


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Measure

Measures taken before the office re-organisation

Data collection retrieval times measured

Information management methods were reviewed

Links to Project Darwin - Improvements to ISO 9001

15 mins

20 minsTIME to retrieve/

reference a doc in library

TIME to retrieve current

PRS files

DUPLICATED

documents

MEASURES

This is a benchmark with each value = 100

0 100

20

PERSONAL storage

space reduction56 filing cabinet drawers

Conduct Kaizen Improvements As Per Factory?


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Implement Actions

Cell Meeting

Data Collection

CustomerConsumer

Factory

Processes

Quality Information

Safety Information

Supplier

6 Big Loss Data Waste

Initiatives

Area Notice Board

Visual Management

Productivity

Problems

t

" If you cannot measure it YOU cannot improve ! "

Conduct Kaizen Improvements As Per Factory?

Process Analysis


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method

Engineeringbrief

materialmachine

man

activity responsible

Project Contract John

Update Project Paul

Project team definition Paul

Procedure (PCP) JohnEngineering Brief Mike

Engineering Contractor William

MP Workshop Paul

Detailed Process John

Design Review Process

time

Eliminate

Combine

Reduce

Simplify

Process Analysis

Before


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Before

The Office Layout at the FirstTPM open day.

Desks and roller cupboards

located at either side of the office.

Walk way in the centre of the office.

Plan and 5S


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Plan and 5S

Plan office improvement - whole team involved

Use 5S as a tool to improve5S Audit Sheet 5S Improvement Sheet

5S Graph shows clearly where

improvements need to be made

Educate people about 5S

Measure

Team: Project Leader& EC Team

Kaizen - 4M analysis

Action Plan

Plan into Action

Record Results

Began

1998

Sort

Set Limits

Shine

Set Standards

Stick to it

Audit

Schedule

Man - Train in 5S

M/C - Workspace Mgmt

Materials -Controls

Method - ISO Procedures

Roger / Rogerio& EC Team

In / Out Board on door shows Improved Layout


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In / Out Board on door shows Improved Layout

TEAM PLAYERS

You Are

Here

KEY

Fire Alarm Call Point

ECngineering

entre

Exit

Exit &

Toilets

Please keep to the Walkway

Technical

Print/Plot

Room

Library

1 2 3 4

5 6

7

8

9 10

11

12

13

14 15

16

17

18

19

2022

21

Entrance

Oasis

Improved Office Layout


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Improved Office Layout

Current office Layout. Current office walkway.

Some of the advantages of the current office layout are:

better Team integration which has improved the dynamics of the office

less distraction from visitors and a better atmosphere for visitors

better layout of project and personal roller cabinets

centrally located oasis

Results


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Results

Results from office improvement

Data collection retrieval times improved

Better communication in a user friendly environment

15 mins

20 minsTIME to retrieve/

reference doc in library

TIME to retrieve current

PRS files

DUPLICATED

documents

RESULTS


0 100

20

PERSONAL storage

space reduction56 filing cabinet drawers

3

14

3

30 Secs

Effective improvement from reorganisation

= central locking of the cupboards.

Filing Systems


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TRIO

476PACK

Filing Systems

Project Roller Cupboard with25% room for expansion.

Range of PRS (Project

Record Sheet) identified.

Project label identifying:

- PRS Number

- Project Title- and Discipline.

More Filing Systems


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Centralised storage of Suppliers

catalogues.

Storage of Personal Files.

Personal roller cupboards, containing only personal files etc. Standards

have been developed to which all personal filling cabinets comply to.

More Filing Systems

Even More Filing Systems


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Even More Filing Systems

Owners name.

ECngineering

entre

Top Draw

No. Description

1

2

3

4

5

6

7

89

10

11

12

13

14

15

16

ECngineeringentre

Part of the standard for filing systems.File available on the HPCE-EC intranet. Roller cupboard with closedproject files, located in the library.

File Management


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g

Focus on restructuring file organisation for electronic

project storage

ISO procedure for filing is the template for manual

and electronic filing, shared drive utilised

Project File Index

Standards and 1-Point Lessons


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Standards and 1 point lessons.


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ISO 9001 Improvement Project


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ISO 9001 Improvement Board.

54 pieces of

paper

Results

Problems

identified

ProblemAnalysed

Measures

Team

Action Plan

194 pieces of

paper

ISO 9001 - Measures & Results


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NUMBER of

Procedures

TIME to do brief (hrs)

PAGES that do not

add value

NUMBER of internal

non-conformances

Number of external

observation notices


8

120

189 (95 Project Brief)

20

0 100

20

ISO 9001FocusedImprovements -

Measures


NUMBER of

Procedures

TIME to do

brief (hrs)

PAGES that do

not add value

NUMBER of internal

non-conformances

Number of external

observation notices

8

120

189 (95 Project Brief)

20

0 100

20

8

2

32

0

0

ISO 9001 Focused Improvements -

Results

Problem: Project brief too long to complete.

Measures: up to 8 hours to complete the project brief.

A team analysed the measures using the CEDAC diagram and formulated an action plan.Result: a reduction in the time to complete the Project Brief, now called Project Contract.

Oasis Area


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The Oasis - time for informal group

discussions and a break from routine work.

Desktop & Movement Board.


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We employ Clean Desk Policy Movement Board

Desk Movement Chart


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Post It's

POST ITHEREPlease use post it notes

provided,and I'll respond

as soon as possible.

Roger Forster

LDC

Training

Europe

Factory

URL UK Factory

Quiet

Office

11223

4567

8910

11

Off Site

Meeting

I Will Be Back!

MT

WTh

F

Story Boards


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Use boards to share current

information

Current Work Processes

FunProject Work

MP Workshop Board.

Inputs

Process ResultsTeam Event Board.

Project Work Board.


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Project Work

MP Workshop Board.


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MP Workshop Board.

Inputs

Process Results

Team Board.


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Team Event Board.

TPM Database.


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TPM Database Board.

Story Boards


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Use boards to share current information

Strategy & Continuing Measurement Training

Quality

Strategy & Policy and Loss Deployment Boards


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Strategy & Policy Board. Loss Deployment Board.

Work Plan and Skills Matrix Boards


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Work Plan Board. Skills Matrix Board.

Quality Board


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Quality Board.

ISO 9001

EC Quality

Manual

EC Standards

EC ProceduresEC Flowcharts

Display Cabinet of Customers Products.


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Display Cabinet.

Continued Improvement using 5s


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Educate people about 5S

Measure

Team: Project Leader

& EC Team

Kaizen - 4M analysis

Action Plan

Plan into Action

Record Results

Began1998

SortSet LimitsShineSet StandardsStick to it

AuditSchedule

Man - Train in 5SM/C - WorkspaceMgmtMaterials -ControlsMethod - ISO Procedures

Roger /Rogerio& EC Team


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Radar Chart - Measure Consistency


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Month Aug-99 Oct-99 Nov-99 Feb-00 May-00 Aug-00 Nov-00 Feb-01 May-01 Aug-01 Nov-01 Feb-02

Score 37 21 18

Responsible Person :

Last Update:

Next update:

5s Radar Chart For: XXXXXX

xxxxx

Feb. 2000

March 2000

0

20

40

60

80

100

Aug-99

Nov-99

Feb-00

May-00

Aug-00

Nov-00

Feb-01

May-01

Aug-01

Nov-01

Feb-02

Month

Score

Aim

20

15

10

5

Seri(Sort)

Seiton

(Set Limits)

Seiso

(Shine)

Seiketsu

(Set Standards)

Shitsuke

(Stick to it)

Aim

3

Horizontal Replication


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Share TPM electronically

Community of Practice - new Web tools

Share TPM personally

Open Days

HPCE Engineering Centre

TPM CD

July 2000

Compact

Discs

Good ideas

to take away


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Remember when applying TPM in the admin...


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RESULTSRESULTS

Supply ChainSupply Chain

+ +

PlanningPlanning

Sourc

e

Source

De

liver

y

De

liver

y

MAKEMAKEMAKE

The Supply Chain Business Process



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InitialProductionProcess

ExternalSuppliers


Inbound Logistics Manufacturing ServiceSales & Marketing

FinalProductionProcess

Transport/Distribution

ReceiptingWarehouseOperations

Workin

Progress

OrderPlanning &Scheduling

Customer Service Process

TransportDistribution

CustomerReceipt

CustomerHandling

ShelfReplenishing

ConsumerInput /

Complaints

Inventory

WarehouseOperations

CustomerInput /

Complaints

HPCEQuality

System

CustomerOrder

OrderProcessing

InnovationProcess

ImproveCurrent

SC System

OrderProcessing

PurchasingInternal

Processing

Sales/Purchasing Process

SupplierDespatch

Inventory

Customer Inventory Control System

RequirementsOut

SuppliesIn

OutboundLogistics

Physical Movement

Information Flow

example of tpm in office europe

Documents