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Transcript of Super factory
1© 2004 Superfactory™. All Rights Reserved.
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This presentation contains the contents pages from most of presentation products. This presentation contains the contents pages from most of presentation products.
Superfactory Excellence Program™Superfactory Excellence Program™www.superfactory.comwww.superfactory.com
2© 2004 Superfactory™. All Rights Reserved.
Lean OverviewLean Overview
1.1. Lean ManufacturingLean Manufacturing
2.2. 5S & Visual Controls5S & Visual Controls
3.3. KaizenKaizen
4.4. Value StreamsValue Streams
5.5. Pull ManufacturingPull Manufacturing
6.6. Mistake ProofingMistake Proofing
7.7. Quick ChangeoverQuick Changeover
8.8. Six SigmaSix Sigma
9.9. Lean AccountingLean Accounting
10.10. Theory of ConstraintsTheory of Constraints
11.11. Human FactorsHuman Factors
3© 2004 Superfactory™. All Rights Reserved.
5S and Visual Control5S and Visual Control
5 Elements of 5S5 Elements of 5S Why 5S?Why 5S? WasteWaste Workplace observationWorkplace observation SSortort SStraightentraighten SShinehine SStandardizetandardize SSustainustain Visual FactoryVisual Factory SummarySummary
4© 2004 Superfactory™. All Rights Reserved.
Activity Based CostingActivity Based Costing
What is Activity Based Costing?What is Activity Based Costing? Cost Accounting SystemsCost Accounting Systems Traditional Cost SystemsTraditional Cost Systems Activity Based CostingActivity Based Costing Implementing ABCImplementing ABC Benefits & Limitations of ABCBenefits & Limitations of ABC Lean AccountingLean Accounting
5© 2004 Superfactory™. All Rights Reserved.
Balanced ScorecardBalanced Scorecard
1. Introduction to the Balanced Scorecard What is it? Why do it?
2. Balanced Scorecard Fundamentals The Four Perspectives Measures, Targets and Initiatives Roles and Responsibilities
3. Using the Balanced Scorecard as a Management System4. Issues and Challenges with the Balanced Scorecard5. Implementing the Balanced Scorecard
6© 2004 Superfactory™. All Rights Reserved.
Cellular Manufacturing / Plant LayoutCellular Manufacturing / Plant Layout
Fundamentals of layoutFundamentals of layout ProcessProcess ProductProduct FixedFixed HybridHybrid
Cellular ManufacturingCellular Manufacturing CharacteristicsCharacteristics Implementing CellsImplementing Cells
Part FamiliesPart Families Production Flow AnalysisProduction Flow Analysis
7© 2004 Superfactory™. All Rights Reserved.
Cost AccountingCost Accounting
Cost Terms, Concepts, and ClassificationsCost Terms, Concepts, and Classifications Job Order CostingJob Order Costing Cost BehaviorCost Behavior Cost – Volume – ProfitCost – Volume – Profit Activity Based CostingActivity Based Costing Profit PlanningProfit Planning Standard CostsStandard Costs Flexible Budgets and Overhead AnalysisFlexible Budgets and Overhead Analysis Relevant Costs for Decision-MakingRelevant Costs for Decision-Making
8© 2004 Superfactory™. All Rights Reserved.
Design of ExperimentsDesign of Experiments
What is Design of Experiments?What is Design of Experiments? MethodMethod
Step 1: Model VariablesStep 1: Model Variables Step 2: Set Variable TargetsStep 2: Set Variable Targets Step 3: Experimental PlanStep 3: Experimental Plan Step 4: TestingStep 4: Testing Step 4: AnalysisStep 4: Analysis
Effects, Replicates & InteractionsEffects, Replicates & Interactions
9© 2004 Superfactory™. All Rights Reserved.
Failure Modes & Effects AnalysisFailure Modes & Effects Analysis What is FMEA?What is FMEA? History History BenefitsBenefits ApplicationsApplications ProcedureProcedure ExerciseExercise SummarySummary
10© 2004 Superfactory™. All Rights Reserved.
Human FactorsHuman Factors
1.1. ErgonomicsErgonomics
2.2. Knowledge ManagementKnowledge Management
3.3. Rewards & RecognitionRewards & Recognition
4.4. Safety & HealthSafety & Health
5.5. Effective TeamsEffective Teams
6.6. Conducting Effective MeetingsConducting Effective Meetings
11© 2004 Superfactory™. All Rights Reserved.
ISO 9001 - 2000ISO 9001 - 2000 IntroductionIntroduction
General IntroductionGeneral Introduction Quality Management PrinciplesQuality Management Principles Process ApproachProcess Approach Compatibility with Other Management SystemsCompatibility with Other Management Systems
Part 1Part 1 Section 1 Scope Section 1 Scope Section 2 Normative reference Section 2 Normative reference Section 3 Terms and definitionsSection 3 Terms and definitions Section 4 Quality Management SystemSection 4 Quality Management System Section 5 Management responsibilitySection 5 Management responsibility Section 6 Resource ManagementSection 6 Resource Management
Part 2Part 2 Section 7.1 – 7.3 Product RealizationSection 7.1 – 7.3 Product Realization
Part 3Part 3 Section 7.4 PurchasingSection 7.4 Purchasing Section 7.5 ProductionSection 7.5 Production Section 7.6 Control of Measuring DevicesSection 7.6 Control of Measuring Devices
Part 4Part 4 Section 8 Measurement, Analysis, and ImprovementSection 8 Measurement, Analysis, and Improvement
12© 2004 Superfactory™. All Rights Reserved.
Job Design & Work MeasurementJob Design & Work Measurement
Job DesignJob Design Job specializationJob specialization Job expansionJob expansion Psychological componentsPsychological components Self-directed teamsSelf-directed teams Motivation and incentive systemsMotivation and incentive systems Ergonomics and work methodsErgonomics and work methods
Work MeasurementWork Measurement Time StudiesTime Studies Work SamplingWork Sampling
Labor StandardsLabor Standards
13© 2004 Superfactory™. All Rights Reserved.
KaizenKaizen
What is Kaizen?What is Kaizen? HistoryHistory How to KaizenHow to Kaizen The Kaizen BlitzThe Kaizen Blitz RoadblocksRoadblocks
14© 2004 Superfactory™. All Rights Reserved.
Knowledge ManagementKnowledge Management
1.1. Why the Interest?Why the Interest?
2.2. Knowledge ManagementKnowledge Management1.1. Trends in Knowledge ManagementTrends in Knowledge Management
2.2. Forms of KnowledgeForms of Knowledge
3.3. Intellectual CapitalIntellectual Capital
4.4. Challenges & Critical Success FactorsChallenges & Critical Success Factors
3.3. Learning OrganizationsLearning Organizations1.1. Team Learning & Personal MasteryTeam Learning & Personal Mastery
15© 2004 Superfactory™. All Rights Reserved.
Mistake Proofing & Poka YokeMistake Proofing & Poka Yoke
What is Mistake Proofing?What is Mistake Proofing? Everyday ExamplesEveryday Examples Effectiveness & ROIEffectiveness & ROI Error Proofing and SPCError Proofing and SPC Inspection TechniquesInspection Techniques Types of Poka YokesTypes of Poka Yokes
16© 2004 Superfactory™. All Rights Reserved.
Forecasting, Planning & SchedulingForecasting, Planning & Scheduling
Forecasting Planning Scheduling MRP & ERP
17© 2004 Superfactory™. All Rights Reserved.
Project ManagementProject Management
PM in today’s environmentPM in today’s environment rapid changerapid change BPRBPR
The project planThe project plan Management & communicationsManagement & communications Organizational, people, political issuesOrganizational, people, political issues StakeholdersStakeholders Tools & methodologiesTools & methodologies
18© 2004 Superfactory™. All Rights Reserved.
Pull ManufacturingPull ManufacturingKanban, One Piece Flow, JITKanban, One Piece Flow, JIT
Why Pull Manufacturing?Why Pull Manufacturing? The Problem of InventoryThe Problem of Inventory Just In TimeJust In Time KanbanKanban One Piece FlowOne Piece Flow Demand / PullDemand / Pull Standard Work & Takt TimeStandard Work & Takt Time Production SmoothingProduction Smoothing
19© 2004 Superfactory™. All Rights Reserved.
Quick Changeover / SMEDQuick Changeover / SMED
Changeover and Changeover TimeChangeover and Changeover Time Traditional SetupTraditional Setup SMEDSMED SMED Process StepsSMED Process Steps Ideas for ImprovementIdeas for Improvement
20© 2004 Superfactory™. All Rights Reserved.
Root Cause AnalysisRoot Cause Analysis
Course ObjectivesCourse Objectives What is Root Cause?What is Root Cause? BenefitsBenefits The Problem Solving ProcessThe Problem Solving Process
Examples and ExercisesExamples and Exercises
21© 2004 Superfactory™. All Rights Reserved.
Six SigmaSix Sigma
What is Six Sigma?What is Six Sigma? Phases of Six SigmaPhases of Six Sigma
DefineDefine MeasureMeasure Evaluate / AnalyzeEvaluate / Analyze ImproveImprove ControlControl
Design for Six SigmaDesign for Six Sigma Green Belts & Black BeltsGreen Belts & Black Belts
22© 2004 Superfactory™. All Rights Reserved.
Statistical Process ControlStatistical Process Control
What is Statistical Process ControlWhat is Statistical Process Control VariabilityVariability Control ChartsControl Charts Process Capability CProcess Capability Cpp
Measuring InstrumentsMeasuring Instruments Repeatability & ReproducibilityRepeatability & Reproducibility
23© 2004 Superfactory™. All Rights Reserved.
Strategic ManagementStrategic Management
Strategic Management ThinkingStrategic Management Thinking The Strategic Management ProcessThe Strategic Management Process Customer AnalysisCustomer Analysis Competitor AnalysisCompetitor Analysis Strategy FormulationStrategy Formulation ExecutionExecution
24© 2004 Superfactory™. All Rights Reserved.
Supply Chain StrategiesSupply Chain Strategies
Strategic Importance of Supply Chains Supply Chain Economics Supply Chain Strategies Managing the Supply Chain Internet Purchasing Vendor Selection Materials Management Benchmarking Metrics Value Chains Global Supply Chains
25© 2004 Superfactory™. All Rights Reserved.
Technology AssessmentTechnology Assessment
Management of TechnologyManagement of Technology Sociotechnical ChangeSociotechnical Change Technology PlanningTechnology Planning Technology ForecastingTechnology Forecasting Managing ForecastingManaging Forecasting Methods and IssuesMethods and Issues LifecyclesLifecycles MonitoringMonitoring Tools for TrendingTools for Trending Extrapolating Technological TrendsExtrapolating Technological Trends Expert OpinionExpert Opinion
26© 2004 Superfactory™. All Rights Reserved.
Theory of ConstraintsTheory of Constraints
1.1. Introduction to ConstraintsIntroduction to Constraints
2.2. Five Steps Of Theory of ConstraintsFive Steps Of Theory of Constraints
3.3. Drum Buffer RopeDrum Buffer Rope
4.4. Evaporating Cloud MethodEvaporating Cloud Method
5.5. The Batch Size ProblemThe Batch Size Problem
6.6. Chain AnalogyChain Analogy
7.7. Issues with TOC Issues with TOC
8.8. Measurements & Financial IssuesMeasurements & Financial Issues
27© 2004 Superfactory™. All Rights Reserved.
Total Productive MaintenanceTotal Productive Maintenance
What is Total Productive MaintenanceWhat is Total Productive Maintenance Origins of TPMOrigins of TPM TPM PrinciplesTPM Principles Components of TPMComponents of TPM
Autonomous MaintenanceAutonomous Maintenance Planned MaintenancePlanned Maintenance Equipment & Process ImprovementEquipment & Process Improvement Early Management of New EquipmentEarly Management of New Equipment Process Quality ManagementProcess Quality Management TPM in the OfficeTPM in the Office
Implementing TPMImplementing TPM TPM BenefitsTPM Benefits Maintenance Management & StrategyMaintenance Management & Strategy
28© 2004 Superfactory™. All Rights Reserved.
Total Quality ManagementTotal Quality Management
What is QualityWhat is Quality Evolution of QualityEvolution of Quality Total Quality ManagementTotal Quality Management Employee InvolvementEmployee Involvement Cost of QualityCost of Quality Quality AwardsQuality Awards The Quality Management SystemThe Quality Management System
1. Leadership1. Leadership 2. Strategic planning2. Strategic planning 3. Customer satisfaction3. Customer satisfaction 4. Performance management4. Performance management 5. Human resources5. Human resources 6. Construction quality6. Construction quality 7. Supplier partnerships7. Supplier partnerships 8. Results8. Results
29© 2004 Superfactory™. All Rights Reserved.
Value StreamsValue Streams
What are Value Streams?What are Value Streams? History - ToyotaHistory - Toyota Identifying the Value StreamsIdentifying the Value Streams Value Stream MappingValue Stream Mapping The Current StateThe Current State The Future StateThe Future State Unique SituationsUnique Situations Enhancing the Future StateEnhancing the Future State Implementing ChangeImplementing Change RoadblocksRoadblocks