multi-company project management applied to manufacturing improvement improving business performance...

Multi-company Project Management applied to

Manufacturing Improvement

Improving Business Performance

Team Implementers, LLCCopyright © 2009

Team Implementers, LLC___________Multi-company Management Solutions

MPM2 Improvement Process Vision

• Improvement Enhancement Project that is highly flexible & integrates the following :– Multi-company Project Management– Equipment Supplier Expertise– Continuous Improvement Experiences– DMAIC improvement methodology– OEE metrics


MPM2 Improvement Categories

• Availability– Reduce Breakdowns

– Reduce Changeover Time (Stack, Coil, Die)

– Minimize Adjustments

• Quality– Defect Reduction

– Minimize Rework

– Reduce Start up Impact

• Performance– Speed Optimization

(Product mix)

– Reduce Idle Time

– Eliminate Minor Stoppages

• Equipment Upgrades– Functionality

– Performance

– Reliability


MPM2 Process - Core Ingredients

• Leadership Team

• Measurement Team

• Improvement Teams– Cross-Functional– Targeted Goal & Timeframe– Matched to Customer resources– Integrated with Customer equipment access


MPM2 Process Outline• Opportunity Assessment -Conducted jointly • Environmental Assessment – Performed by Assessor • Contract with Customer to Implement MPM2

• Leadership Team Formation – MPM2 Awareness, Plan Measurement Team• Measurement Team -Formation and measurement of current state• Leadership Team Improvement Planning - Set Goals, Organize

Improvement Teams• Multiple Improvement Teams (simultaneous, overlapping, or sequential)

1st on site event – Analyze & make improvementsHomework – Complete assignments from 1st event2nd on site event – Verify, adjust, standardize improvementsFinal Homework – Complete training, incorporate on other shifts, etc.

• Leadership receives report outs from each improvement team event• Validation – Measurement Team validates results over specified time• Leadership Close Out - Summarize results and lessons learned

Generic MPM2 Process Gantt Chart


Process Activity

MPM2 Timeline

Strategic AssessmentOpportunity

Environmental

Contract Agreement

Leadership Formation

Measurement Team

Improvement Planning

Improvement Team AEvent I

HomeworkEvent II

Improvement Team BEvent I

HomeworkEvent II

Final Homework

Measurement/Validation

Leadership Close Out

31 32

Calendar Weeks27 28 29 3023 24 251 2 3 4 1210 2619 20 21 225 6 7 8 9 11 17 1813 14 15 16


Strategic Assessment Purpose/Structure

• Protect Participants from investing in a process that does not achieve results.

• Three Part Strategic Assessment process Part 1 Scope – Define operations to be improved Part 2 Opportunity - Determine gap between

engineered & actual performance; Verify demand for increased capability.

Part 3 Environment - Determine organization fit to implement the MPM2

• Completely confidential


Part 2 - Opportunity Assessment

• Ideal capacity assumes following:– Zero breakdowns– Zero defects & rework– Optimum operating speeds, feeds, set up, etc.

• Ideal capacity for specified period determined by equipment supplier based on design/use.

• Current state determined from actual production records for specified period.

• Opportunity determined by finding the difference between ideal and current state capacity.

• Demand forecast reviewed to insure utilization of new capacity created by improvements.


Part 3 - Environmental Assessment

• Evaluates (8) parameters– Supportive Leadership - Continuous

Improvement

– Effective Teams - Basic PM Process

– Standardized Procedures - Flexible Work Rules

– Work Place Organization - Willingness to Learn

• Highly subjective over 24-36 hour period

• Uses P-I-F rating for each parameter.

• If any parameter fails, MPM2 process is delayed until parameter improves to I of P.


MPM2 Process Benefits

• Compliments existing systems• Incorporates existing improvement ideas• No disruption of existing teams or processes• Utilizes short term cross-functional teams

with a targeted goal and event timeframe• Team resources matched to manufacturing• Events are integrated with equipment access


MPM2 Process Benefits (cont’d)

• Consolidates Customer & Supplier experiences

• Increases focus on improvement efforts

• Sets clear priorities & high level decisions

• Applies PM & Lean tools/techniques

• Focuses engineering expertise on improvement

• Leadership links all stakeholders

• Double Digit OEE improvements

multi-company project management applied to manufacturing improvement improving business performance...

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