strategic improvement project

Strategic improvement project

Extent of involvement of Team Members

* 1. Are cell members organized as a team? No team formed

25 % of cell members are organized as

team


team


team

100 % of cell

members are

organized as team

2. Are team members stable for 6 months in their own cell? Less than 25 % of

team members 25 % of team

members 50 % of team

members 75 % of team

members

100 % of team

members

3. Is there a designated team activity area in the cell? No concept

No designated area, team

meetings held at random places

Team area defined but no activity

evident

Area defined and some team related information posted

Team activity

performed & related

information posted and regularly

updated on Team Activity

Board

4. Is there a system of giving time for teams to carry out improvement activities?

No concept Adhoc meetings

> 30 min/ week within shift timing Team members

work extra time if required

>1 hrs/ week within shift timing Team members

work extra time if required

> 2 hrs/ week within shift

timing

Communication

5. Is there a system of formal communication from management to employees?

No formal communication

Some adhoc communication

flow

Communication given to leaders

only

Communication displayed at the

team activity area.

Monthly communicatio

n meeting.

6. What is the extent of information given to team by management?

Communication restricted only to daily production

targets

Few major issues like customer complaints are

communicated to team

All customer related information is communicated

Information on new developments,

targets & achievements

Total transparent

system, team has access to all business

related information

7. Is there free communication between team members? No communication Intra team

communication started

Free communication between team

members

Inter team communication

with preceding and next step teams

Free communication between all teams across

plant

8. Are regular team meetings held for better communication? Is there a meeting schedule?

No schedule available

Schedule available but 25% meetings

held as per schedule

50% meetings held as per schedule

75% meetings held as per schedule

100 % meetings held

as per schedule

9. Do all members participate during team meetings and what is their participation level

Attendance not monitored

Attendance recorded but only

25 % team members attend

meetings


meetings


meetings

100 % team members

attend meetings

10. Are proceedings of team meeting recorded? Minutes of meeting

not prepared

Minutes prepared but not circulated to all concerned

Minutes prepared but no action plans

Minutes prepared with clear action

plan and responsibilities but

no follow up

Minutes of meeting

prepared with clear action

plan and responsibilities, and progress

tracked.

11. Are team meetings structured and controlled? No

Suddenly called meetings with no

control over the time spent in

meeting

Meeting is preplanned but

agenda not clear to all members

Agenda circulated in advance but some members

come un-prepared

Meetings finished within designated

time but sometimes without

conclusion

Agenda communicated

well in advance to all

team members and

members come

prepared for the meeting and honor

timings

Improvement projects by team

12. Has team identified time bound projects for making improvements in the work unit?

No projects defined

Areas requiring improvement

identified, but no

time bound projects identified

Improvement projects identified but responsibilities

for completion not clear

Projects identified with clear

responsibilities but

phase-wise time plan not prepared

Projects identified and

detailed project charter

prepared and displayed in team area

13. Have the project teams been formed? Members work independently

Project team formed

Team meets regularly and

project driven by the leader

Team uses brainstorming

methodology to gather ideas from

all members

Team explores various

options before finalizing on causes and

solutions

14. Do the teams demonstrate interpersonal trust and free communication?

Poor communication

Communication restricted to small

subgroups

Interpersonal trust started building

and leader encourages members to communicate

High level of interpersonal trust but some members apprehensive about speaking out their

mind

High level of interpersonal trust and free communicatio

n between team

members

15. Are the members clear about their roles in project completion? Not clear

Members start working on

individual tasks picked on their own

Project leader defines and

communicates each member’s task.

Members clear about individual

roles but co-ordination with

other members not good

All the members are clear about

their roles and linkages of

their individual efforts

established with main

project

16. Are the timelines clear to all members for project completion? Is the progress on these projects tracked?

No clear targets for project

Target date set for completion of project, but

stepwise time plan not available

Project broken down to small

tasks with clear start and end point and clear time plan

for completion of each task.

Adhoc tracking

Individual tasks & main project progress is

monitored but

countermeasures not available in case of gaps

Team regularly

reviews the progress and takes action

wherever targets are not

met.

17. What is the participation level of members for completion of these projects? (Do all members contribute?)

Project leader considered

responsible for project completion

>25 % members contribute for

project completion

> 50 % members contribute for

project completion

> 75% members contribute for

project completion

100% members

contribute for project

completion

18. How many improvement projects are completed by team? Nil < 2 projects/year >= 2 projects/year >= 4 projects/year >= 6

projects/year

19. Is there a system to motivate members for speedy completion of projects?

No motivation Appreciation by

front line supervisor

Awards & recognition

Performance KRAs linked to project

completion.

Selected projects are

nominated for group-wide

QCDGP award

Shop floor Discipline & Decision Making

20. Are the shop-floor discipline (rules) communicated? No evidence

Informal

communication

Doc are displayed at prominent

location in Shop

< 50% of WU members are

aware

> 100% of WU members are

aware and

Floor follow

21. Do team members (Incl Casuals) follow safety rules? No evidence Few safety rules as

defined are followed

All PPE's as defined are used

PPE'S with safety Instruction for m/c

followed

100 % of safety rules are followed

22. Do team members follow Quality rules? No concept All process have

well defined SOP/WI

Poka-Yoke + 1st part is checked and

documented

Rework are done as per specification

by authorized person

100% of the Quality rules are followed

23. Is Man Machine allocation as per skill matrix Adhoc < 25% adherence

for short term < 50% adherence

for short term < 75% adherence

for short term

> 100 % adherence for

at least 6 months

24. Who takes decision if Safety, Quality & Skill based machine Allocation rules are not followed?

Adhoc Any Shop Floor

Manager Shift/Production In-

charge Cell Leader WU Member

*25.

Is there Unplanned Absenteeism in the team? (Avg. data of last 6 months)

High but monitored

<2 % < 1% <0.5 <0.25

Idea Implementation

Idea Focus

1. Do team members focus only on one category of PQCDSM while giving ideas?

One category only 2 categories 3 categories 4-5 categories Improving PQCDSM

2. Is improvement in quality of product & process a focus area for ideas?

No Improvement in one workstation

Improvement in other workstations within work unit

Improvement in other workstations across work unit

Improvement across

workunit and beyond

workplace

3. Are ideas given to improve productivity, cost and delivery performance for work-unit?

No Improvement in one workstation



Improvement across work-

unit and beyond

workplace

4. Are ideas given to improve safety and morale? No Improvement in one workstation



Improvement across

workunit and beyond

workplace

Idea Approval

5. Are team members clear about the procedure of getting approvals for ideas?

No procedure for clearance

No set procedure, some adhoc approvals

Procedure exits but not communicated

to members

Team members approach the

leader, who in turn gets all the approvals

All team

members clearly

understand and follow

the procedure.

6. Are approvals given quickly for speedy implementation of ideas?

Delayed approvals, mostly

rejections

Quick approvals for ideas

involving low cost

Timely approval for < 50 % ideas

Timely approval for < 75% ideas

Approval done within

time as stipulated in

the idea

procedure

7. Is the team involved in discussions while approving the ideas?

Team not involved at all

Team member involved for

Safety, Visual Mgmt & 5S

Ideas

Team member involved for

Ergonomics & Layout Ideas

Team members are involved for Quality, Cost &

Productivity related Ideas

Team members are involved for

all categories of Idea in PQCDSM

8. Is the team empowered to approve its own ideas? Team not

empowered

Team empowered to approve ideas

related to 5S at work place

Team empowered to approve ideas related to safety

and visual management at

work place

Team empowered to approve productivity related ideas

Team empowered to approve

100 % ideas.

9. In case of a non-approved idea, are the reasons for rejection clearly communicated to team members?

Not communicated Communicated

for > 25 % ideas

Communicated for > 50 % ideas

Communicated for > 75 % ideas

Reasons clearly

communicated and area of IMPRV also discussed

Idea implementation

10. What is the system for implementation of given ideas? By outside agencies

Improvement corner created

WU members have ability to make

small improvements with

cross functional help (TSG/Maint)

WU members have ability to create low

cost automation with cross

functional help (TSG/Maint)

Work unit has ability to make small

improvements and low

cost automation

without cross

functional help

11. What is the time lag between idea given and implemented? Not tracked Within a year Within 3 months Within 1 month <15 days

12. Who is responsible for implementing ideas? Ideas

implemented by outside agency

TSG/Maint team members help the person for implementation

Team leader helps in implementation

Work unit team implements the

idea

Idea implemented

by the originator.

13. Are Kaizen Sheets prepared and shared with all members for Implemented Ideas

Not Used Started but not

consistent

Consistency in Practice is observed

Best – 3 Ideas of PQCDSM

Best Idea in each of the category of PQCDSM

14. Do team members maintain record of ideas given/implemented (e.g. OE growth file)

No record kept Record of only implemented

ideas

HR department keeps the record

Supervisor keeps the record

Team members keep a

record of all given/

implemented ideas in their growth file

15. Does Management provide support for improvement activities

No support

Management communicates ideas scheme

and give simple rewards for

good proposals

Resources provided in few cases

Autonomous improvement

activities

Improvement activities go smoothly without much

support from management

16. Are team members skilled to implement their ideas

Team members completely

depend on outside agencies

Team members able to

implement ideas with little help from external agencies like

maintenance or vendor

Team members

able to make prototypes

Team members help each other in

idea implementation

Team members able to

implement ideas on their own

Ideas impact

17. Is the impact of idea checked/ evaluated? No evaluation Impact

evaluation by supervisor

Self Eval by originators & Eval.

Comm. for few ideas

Self Eval by originators for all

ideas

All the Ideas are Eval for Impact by the Eval.

Comm. after going thru

the Self Eval

18. Are ideas evaluated for one-time benefits only? Not evaluated One time

benefit limited to machine

Short term benefits limited to work unit

Mid-term benefits across plant

Long term benefits

across plant

19. Are benefits generated by ideas, replicated horizontally in areas also?

No

Horizontal deployment on

similar machines only

across the workunit

100 % deployment across work-unit

>50 % horizontal deployment across

plant

100 % horizontal

deployment across plant

Motivation for ideas

*20. Is there a structured program available to encourage team members to give ideas?

No formal system of

collecting and implementing

ideas

Formal ideas program

launched in cell

Visually attractive idea box & motivating

posters encourage team members to give

ideas

Companywide ideas program

launched

All ideas collected

and scrutinized

by committee and records

kept

*21. Do all team members participate in ideas program and also Implement ? (avg data of last 6 months) , (for scoring Lowest of the criteria score to be considered)

< 10 % people & 0.5 Idea per person /month

> 10 % people & < 1 Idea

per person/m

onth

>50% people & > 1 Idea per

person /month

> 80 % people & > 2 Ideas per

person /month

>95% people & > 4 Ideas per

person /month

22. What motivation is given to team members to give ideas? No motivation Awards &

recognition for

ideas

Ideas are linked to performance

appraisal

Team members sent to other plants

to learn best practices and

implement the same in their own

work area

Staff members

who work on m/c give Idea to that team member in Idea/Sugg

form

23. Is there a system to project implemented ideas at higher levels?

No Displayed in team area

Best ideas presented in

company communication

meetings

Best ideas presented at group

level

Best ideas are sent to

outside forums

Training

24. Is there a structured program to develop/Instill Idea generation to members?

No Program

development has started.

Structured Program

developed to focus on 7 wastes, 16

losses from shop floor examples

Developed program covers

< 75 % members

Developed program

covers > 75 %

members

25. Has all the cell leaders, Production Supervisors are exposed to latest technology advancement?

No system Training just

started covers < 25%

Coverage > 75% Coverage is 100%

Structured programs

identified and system is

well established

strategic improvement project

Design