Session 5

Review A3 progress

•Error Proofing

•Visual Control

•Workplace organisation

•Standard Operating Procedures

Quality – Right First Time

• High level of waste generated from ‘rework’• Due to– Incorrect data– Incorrect process / Instructions– Errors– Changes made in one department have an

adverse effect on another– Lack of training in the ‘full process’

Quality - How to Improve

• Give examples of quality issues seen within your department

• How can these be addressed

Quality - Improvements

• Standardised work / instructions • Training• Understanding of the ‘full process’• Own data• 100% data accuracy• Prevent errors

Can we Inspect Quality in

• Read this sentence: FINISHED FILES ARE THE RESULT OF YEARS OF SCIENTIFIC STUDY COMBINED WITH THE EXPERIENCE OF YEARS.

• Now count the F's in that sentence. Count them only once, only once: do not go back and count them again.

Error Prevention

• Known as Poke Yoke• Aims to produce defect free products to the

next process• Identify and / or prevent error at source• eg• - can not start• - cannot release• - cannot pass

Practical Example

• Using the instructions card, grid and coding conventions please complete a Card 1 in 5 minutes.

• What difficulties did you have (concerns)• What was the reason for them (causes)• How can these be eliminated and improved

(countermeasures)• Try using a Cause, concern and countermeasure

board (three columns)to collate your thoughts.

Example: Colour Coding

Example: Computer forms

Example: Filing

Visual Controls

• Industry – 3 minute rule– Anyone walking into the factory can immediately see

if production is on time– If there are any quality issues– If the plant is functioning correctly

• Could I walk into your office and immediately know– Are all tasks on time– Are there any issues outstanding

Visual Controls

• Can be split into 2 types– Housekeeping and quality (this session)– Progress and monitors (next session)

Housekeeping & Quality : Examples

• Colours– Different coloured folders for each academic year– Red copies for urgent work to be done

immediately (eg module change forms in registry)– Red Amber Green (RAG), but used more for

monitoring

Visual Replenishment Systems

Visual Replenishment Systems

Cell Performance Board•Takt

•Capacity Plan

•Production Plan

•Standard Ops

•OEE

•Delivery

•Reason codes

•Parts per person

•Downtime

Work Place Audit Board

Skill Matrix

Visual Management Conclusions

• Simple Communication• Easily understandable• Continuously updated• Accessible to EVERYONE

• How can you use this within your area?

Workplace organisation (5’S)• What is it?– A methodology of improving our workplace– Sort, Sweep, Set, Standardise and Sustain – A place for everything and everything in its place

• Why do it?– Makes for a better working environment– Makes it easier to see when things are missing– Makes it easier to find the everyday used

objects/work

How do we carryout a 5’s activity

Step one Sort

•Identify an area that is in need of improvement.•Setup a RED tag auction area •Remove all unwanted or unnecessary things from the immediate work place

My own work space sort

How do we carryout a 5’s activity

Step Two Sweep

•Deep clean the area, leave no place untouched

My own workspace Sweep

How do we carryout a 5’s activityStep Three Set

•From the items remaining (the one’s you have not thrown or given away) identify which you use•Every day, Once a week•Once a month, Once a year

•only place the items that you use on a daily weekly basis back into the work area, all other items find suitable storage

My own workplace Set

How do we carryout a 5’s activityStep Four Standardise

•Place the items where they are going to be most accessible to everyone, if shared then gain consensus from the group

•You could mark around the items to show where they should be for later reference but only when everyone is agreed that this is the best layout

•Take a picture of the desired state as a reference

My own workplace Standardise

How do we carryout a 5’s activityStep Five Sustain, the most difficult and often the hardest part of 5’s

•Ensure everyone works to the new system and record changes that are made with improvements.

•To help, measure firstly on a weekly bases and then monthly basis the desired against the actual using your standard.

Sustain audit check list

Standard operating procedures•What are they?•A methodology of giving simple instructions•Pictures •Flow charts•Written instructions•Mixture of all of the above

•Why do we need them•Repeatability•Training aids•Measurement guides•Etc.

Standard operating procedures

•SOP Activity

•From the following verbal communication make an item using the equipment / materials provided

Standard Operating Procedures

•SOP Activity

•From the following SOP Make the item using the equipment / materials provided as part of a group process.