Our Improvement Story Board
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Lean Management
Teachers
Our Improvement
Story Board
Ideas building on Mike Rothers work using
recent experience with beginning
practitioners.
March 2012 Emiel van Est
![Page 2: Our Improvement Story Board](https://reader034.fdocuments.in/reader034/viewer/2022052522/554c5221b4c905452e8b4859/html5/thumbnails/2.jpg)
Our Improvement Story
We practice the Improvement Kata & Coaching Kata as
outlined in Mike Rothers Book Toyota Kata and the
companion Handbook
© Lean Management Teachers 2
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1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
We used the Process Analysis Mini Kata to
Understand our Current Condition.
3 © Lean Management Teachers
Customer Demand and Line Pace
• Customer takt
• Planned cycle time
• Number of shifts currently running
Overview of the Process
• Define the start & end points of the process
•Get to know the process by sketching a block diagram of it
- Where does WIP accumulate?
• How much does process output fluctuate? (Cycle-to-cycle and shift-to-shift)
• Note other details about the current operating pattern
Machine Capacity
• Can the automatic equipment support the planned cycle time?
• How close are we to our current machine capacity limit?
•What is the fastest Pc/t the equipment can currently support?
• Shift options?
Process Fluctuation
• Time 20-40 full cycles of each operatorʼs work
•Are each operatorʼs work steps the same from cycle to cycle?
No Yes
No Yes
Necessary Number of Operators (if process were stable)
• Calculate number of operators
-- Example 2 --All-in-one summary for a manual line
Customer Demand / Line Pace
• Takt Time = 30 seconds • PC/T = 22 seconds • Gap = 27% • Running 2 Shifts + overtime • 10 changeovers per day
40 Overview
35 • Output cycles vary +/- 109% • Operator work steps vary • 4 operators TT • WIP (as shown) • Line does not meet Pc/t 25
and must run overtime Pc/t 20
Machine Capacity 90%
CURRENT CONDITION
Process
Date
Range of observed cycle times
Lowest repeatable
observed cycle time
• Op 90 cannot meet Pc/t (see chart)
Process Stability
• Operator cycles fluctuate
of Pc/t 15
10
5 I I I I up to -30% / + 90% (see chart)
• Operator 4 cannot consistently meet Pc/t
Necessary Number of Operators
• 3.2 operators / 4 actual • Operators 1, 2 & 3
are underutilized (see chart)
5 2 12 pcs pcs pcs
10 40 70
Machines
22 pcs
90 110
Operators
© Improvement Kata Handbook Current Condition 50
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1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
We filled in our Target Condition Form
4 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
WHAT INFORMATION IS IN A TARGET CONDITION? A target condition describes how you want a process to operate
• A target condition for a manufacturing process should include the following four categories of information.
• No verbs in a target condition. Thatʼs for how to get there.
• You must include a target date for achieving the target condition.
Achieve-By Date: (required)
(1) DESCRIBE PROCESS STEPS, SEQUENCE & TIMES
A pattern you can draw or chart (see example)
(2) OTHER PROCESS CHARACTERISTICS
Used for improving
Used to check
outcomes
Examples: • Number of operators • Number of shifts •Where 1x1 flow is planned, and where standard WIP
(incl. quantity) is to be located • Leveling sequence
(3) PROCESS METRIC(S) (Measurement in the moment)
For checking process condition in real time Examples: • Time for each step, piece, pitch, etc.
• Degree of time fluctuation from cycle to cycle
(4) OUTCOME METRIC(S)
To check outcome of improvement efforts Examples: • Number of pieces per hour or shift
• Leveling sequence attainment • Productivity
© Improvement Kata Handbook Target Condition 11
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1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
Now we are here mixing things up during
coaching sessions.
5 © Lean Management Teachers
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1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
Quite often, Q2 is answered by the Current
Condition we came from,..
6 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
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1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
... instead of referring to Today's Current
Condition …
7 © Lean Management Teachers
Our Gemba
Go & See
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1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
… or this section is updated every PDCA
cycle
8 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
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Lean Management
Teachers
Maybe we can make things
easier to understand
© Lean Management Teachers 9
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1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
Lets cut the Target Condition Form in two
and add a date for the starting Current Condition
to clearly distinct starting point and targeted point.
10 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Date
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1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
In between we can list all relevant information
about our discovery process.
11 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Date
Our Gemba
Go & See
![Page 12: Our Improvement Story Board](https://reader034.fdocuments.in/reader034/viewer/2022052522/554c5221b4c905452e8b4859/html5/thumbnails/12.jpg)
Lean Management
Teachers
Lets test our redesigned
Improvement Story Board
© Lean Management Teachers 12
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Our Improvement Story
Q1 Our Target Condition
13 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Date
-- Example 2 --All-in-one summary for a manual line
Customer Demand / Line Pace
• Takt Time = 30 seconds • PC/T = 22 seconds • Gap = 27% • Running 2 Shifts + overtime • 10 changeovers per day
40 Overview
35 • Output cycles vary +/- 109% • Operator work steps vary • 4 operators TT • WIP (as shown) • Line does not meet Pc/t 25
and must run overtime Pc/t 20
Machine Capacity 90%
CURRENT CONDITION
Process
Date
Range of observed cycle times
Lowest repeatable
observed cycle time
• Op 90 cannot meet Pc/t (see chart)
Process Stability
• Operator cycles fluctuate
of Pc/t 15
10
5 I I I I up to -30% / + 90% (see chart)
• Operator 4 cannot consistently meet Pc/t
Necessary Number of Operators
• 3.2 operators / 4 actual • Operators 1, 2 & 3
are underutilized (see chart)
5 2 12 pcs pcs pcs
10 40 70
Machines
22 pcs
90 110
Operators
© Improvement Kata Handbook Current Condition 50
90 110
4 4 5 6 3 4
70 3
2 1 3 2 1 2 1
40 10
1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
Our Gemba
Go & See
![Page 14: Our Improvement Story Board](https://reader034.fdocuments.in/reader034/viewer/2022052522/554c5221b4c905452e8b4859/html5/thumbnails/14.jpg)
Our Improvement Story
Q2 Our Current Condition
14 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Date
-- Example 2 --All-in-one summary for a manual line
Customer Demand / Line Pace
• Takt Time = 30 seconds • PC/T = 22 seconds • Gap = 27% • Running 2 Shifts + overtime • 10 changeovers per day
40 Overview
35 • Output cycles vary +/- 109% • Operator work steps vary • 4 operators TT • WIP (as shown) • Line does not meet Pc/t 25
and must run overtime Pc/t 20
Machine Capacity 90%
CURRENT CONDITION
Process
Date
Range of observed cycle times
Lowest repeatable
observed cycle time
• Op 90 cannot meet Pc/t (see chart)
Process Stability
• Operator cycles fluctuate
of Pc/t 15
10
5 I I I I up to -30% / + 90% (see chart)
• Operator 4 cannot consistently meet Pc/t
Necessary Number of Operators
• 3.2 operators / 4 actual • Operators 1, 2 & 3
are underutilized (see chart)
5 2 12 pcs pcs pcs
10 40 70
Machines
22 pcs
90 110
Operators
© Improvement Kata Handbook Current Condition 50
90 110
4 4 5 6 3 4
70 3
2 1 3 2 1 2 1
40 10
1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
Our Gemba
Go & See
![Page 15: Our Improvement Story Board](https://reader034.fdocuments.in/reader034/viewer/2022052522/554c5221b4c905452e8b4859/html5/thumbnails/15.jpg)
Our Improvement Story
Q3 Our obstacles
15 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Date
-- Example 2 --All-in-one summary for a manual line
Customer Demand / Line Pace
• Takt Time = 30 seconds • PC/T = 22 seconds • Gap = 27% • Running 2 Shifts + overtime • 10 changeovers per day
40 Overview
35 • Output cycles vary +/- 109% • Operator work steps vary • 4 operators TT • WIP (as shown) • Line does not meet Pc/t 25
and must run overtime Pc/t 20
Machine Capacity 90%
CURRENT CONDITION
Process
Date
Range of observed cycle times
Lowest repeatable
observed cycle time
• Op 90 cannot meet Pc/t (see chart)
Process Stability
• Operator cycles fluctuate
of Pc/t 15
10
5 I I I I up to -30% / + 90% (see chart)
• Operator 4 cannot consistently meet Pc/t
Necessary Number of Operators
• 3.2 operators / 4 actual • Operators 1, 2 & 3
are underutilized (see chart)
5 2 12 pcs pcs pcs
10 40 70
Machines
22 pcs
90 110
Operators
© Improvement Kata Handbook Current Condition 50
90 110
4 4 5 6 3 4
70 3
2 1 3 2 1 2 1
40 10
1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
Our Gemba
Go & See
![Page 16: Our Improvement Story Board](https://reader034.fdocuments.in/reader034/viewer/2022052522/554c5221b4c905452e8b4859/html5/thumbnails/16.jpg)
Our Improvement Story
Our reflection
16 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Date
-- Example 2 --All-in-one summary for a manual line
Customer Demand / Line Pace
• Takt Time = 30 seconds • PC/T = 22 seconds • Gap = 27% • Running 2 Shifts + overtime • 10 changeovers per day
40 Overview
35 • Output cycles vary +/- 109% • Operator work steps vary • 4 operators TT • WIP (as shown) • Line does not meet Pc/t 25
and must run overtime Pc/t 20
Machine Capacity 90%
CURRENT CONDITION
Process
Date
Range of observed cycle times
Lowest repeatable
observed cycle time
• Op 90 cannot meet Pc/t (see chart)
Process Stability
• Operator cycles fluctuate
of Pc/t 15
10
5 I I I I up to -30% / + 90% (see chart)
• Operator 4 cannot consistently meet Pc/t
Necessary Number of Operators
• 3.2 operators / 4 actual • Operators 1, 2 & 3
are underutilized (see chart)
5 2 12 pcs pcs pcs
10 40 70
Machines
22 pcs
90 110
Operators
© Improvement Kata Handbook Current Condition 50
90 110
4 4 5 6 3 4
70 3
2 1 3 2 1 2 1
40 10
Reflect on the Last Step Taken
Because you donʼt actually know
what the result of a step will be!
1) What was your last step?
2) What actually happened?
3) What did you learn?
----------------------------> Return
1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
Our Gemba
Go & See
![Page 17: Our Improvement Story Board](https://reader034.fdocuments.in/reader034/viewer/2022052522/554c5221b4c905452e8b4859/html5/thumbnails/17.jpg)
Our Improvement Story
Q4 Our next step
17 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Date
-- Example 2 --All-in-one summary for a manual line
Customer Demand / Line Pace
• Takt Time = 30 seconds • PC/T = 22 seconds • Gap = 27% • Running 2 Shifts + overtime • 10 changeovers per day
40 Overview
35 • Output cycles vary +/- 109% • Operator work steps vary • 4 operators TT • WIP (as shown) • Line does not meet Pc/t 25
and must run overtime Pc/t 20
Machine Capacity 90%
CURRENT CONDITION
Process
Date
Range of observed cycle times
Lowest repeatable
observed cycle time
• Op 90 cannot meet Pc/t (see chart)
Process Stability
• Operator cycles fluctuate
of Pc/t 15
10
5 I I I I up to -30% / + 90% (see chart)
• Operator 4 cannot consistently meet Pc/t
Necessary Number of Operators
• 3.2 operators / 4 actual • Operators 1, 2 & 3
are underutilized (see chart)
5 2 12 pcs pcs pcs
10 40 70
Machines
22 pcs
90 110
Operators
© Improvement Kata Handbook Current Condition 50
90 110
4 4 5 6 3 4
70 3
2 1 3 2 1 2 1
40 10
1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
Our Gemba
Go & See
![Page 18: Our Improvement Story Board](https://reader034.fdocuments.in/reader034/viewer/2022052522/554c5221b4c905452e8b4859/html5/thumbnails/18.jpg)
Our Improvement Story
Q5 Our next coaching cycle
18 © Lean Management Teachers
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Process: Challenge: TC date:
Theme of this TC:
Step 1: Fill in current condition data
Current Condition
Target Condition
Step 2: Fill in what you will keep
the same
Step 3: Fill in what you want to change
Takt time: Takt time:
Pc/t: Pc/t:
# of Shifts: # of Shifts:
Overtime (how much): Overtime:
Output / Shift (run chart): Output / Shift:
# of Operators: # of Operators:
Where 1x1, where WIP: Where 1x1, where WIP:
Describe the process Describe the processsteps, sequence, times: steps, sequence, times:
Exit cycle fluctuation %: Exit cycle fluctuation %:
Other observations about the current pattern:
Process Metric:
Outcome Metric:
© Improvement Kata Handbook Target Condition 23
Date
-- Example 2 --All-in-one summary for a manual line
Customer Demand / Line Pace
• Takt Time = 30 seconds • PC/T = 22 seconds • Gap = 27% • Running 2 Shifts + overtime • 10 changeovers per day
40 Overview
35 • Output cycles vary +/- 109% • Operator work steps vary • 4 operators TT • WIP (as shown) • Line does not meet Pc/t 25
and must run overtime Pc/t 20
Machine Capacity 90%
CURRENT CONDITION
Process
Date
Range of observed cycle times
Lowest repeatable
observed cycle time
• Op 90 cannot meet Pc/t (see chart)
Process Stability
• Operator cycles fluctuate
of Pc/t 15
10
5 I I I I up to -30% / + 90% (see chart)
• Operator 4 cannot consistently meet Pc/t
Necessary Number of Operators
• 3.2 operators / 4 actual • Operators 1, 2 & 3
are underutilized (see chart)
5 2 12 pcs pcs pcs
10 40 70
Machines
22 pcs
90 110
Operators
© Improvement Kata Handbook Current Condition 50
90 110
4 4 5 6 3 4
70 3
2 1 3 2 1 2 1
40 10
1
Challenge
& Vision
3
We want
to be here
4
Now we are here,
using PDCA to overcome obstacles
2
We were
here
Our Gemba
Go & See
![Page 19: Our Improvement Story Board](https://reader034.fdocuments.in/reader034/viewer/2022052522/554c5221b4c905452e8b4859/html5/thumbnails/19.jpg)
Lean Management
Teachers
What do you think?
Is this an improvement?
Let me know!
© Lean Management Teachers 19