information centers charts and graphs
TRANSCRIPT
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1Marek Piatkowski FSP Consulting Inc.
Information CentersInformation Centers
Charts and GraphsCharts and Graphs
Marek PiatkowskiJanuary 2011
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2Marek Piatkowski FSP Consulting Inc.
THE QUALITY Q
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T
O
T
A
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No Customer Issues Customer Issu
COLORED LEGEND:
GREEN RED
MONTH YEAR DEPARTMENT
__________ ________ _______________
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DELIVERYMonth Year Line
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THE
DELIVERY
D
COLOR LEGEND
GREEN = NO MISSED SHIPS
OR PREMIUM
RED = MISSED SHIPS
OR PREMIUM FREIGHT
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350
STATORS CASTINGS POTTES
350
700 700
STOCK DE SECURITE ALTERNATEUR LIQUID COOLED
Besoin 3300 pour
re-amnagement
Besoin 400 pour
re-amnagement
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SAFETY
Month-_____ Year- 2000 Line- ______
A SAFE DAY = GREEN
AN OSHA RECORDABLE EVENT = YELLOW
A LOST DAY OCCUPATIONAL INJURY =RED
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LINE ISSUES BOARD
Completion
DateAssigned to Status / Update
Target
DateDate
Location of
ProblemDescription of Problem
Identified
by
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9Marek Piatkowski FSP Consulting Inc.
Monthly Productivity Chart Month:
100% Part #:95%
90%
85%
80%
75%
70%
65%
60%
55%
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
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Monthly Productivity Chart Month:
100% Part #:95%
90%
85%
80%
75%
70%
65%
60%
55%
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
100% Part #:95%
90%
85%
80%
75%
70%
65%
60%
55%
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
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GOAL=_______PP FIRST TIME THROUGH QUALITY (Daily)
PPM
MONTH YEAR DEPT Delphi Confidential
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
TOTAL INSPECTEDTOTAL REJECTED
TOP CAUSES
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Weekly Scrap Chart Manufacturign Cell: Week Ending:
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3
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
1 Destruct 11 Lamination 21 Rerun
2 End/Start of coil 12 Mis-hit 22 Broken/chipped die3 Marks on surface 13 Purchased material 23 Old level parts
4 Bent 14 Setup scrap 24 Handling damage
5 Out of tolerance 15 Defective welds 25 Missing holes
6 Feed off 16 Welds burned hole 26 Holes off location
7 Misformed 17 Auto welder/bent 27 Scrap in die
8 Misgauged 18 Short or no trim 28 Tool room work
9 Rust 19 Bad nuts/threads 29 Defective component part
10 Cracking 20 Overlap
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Line: Weekly Production Schedule Week of:
Prod.
Day Sched. Actual +/- Sched. Actual +/- Sched. Actual +/- Sched. Actual +/-
YF1T-13A803-AC
Mon. YL3T-13A803-AB
YF1T-13A803-AC
Tues. YL3T-13A803-AB
YF1T-13A803-AC
Wed. YL3T-13A803-AB
YF1T-13A803-AC
Thurs. YL3T-13A803-AB
YF1T-13A803-AC
Fri. YL3T-13A803-AB
YF1T-13A803-AC
Sat. YL3T-13A803-AB
Part #2nd Shift 3rd Shift Accum. Weekly Totals1st Shift
l
l
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Model ACM 138 ACM 251 ACM 031
Max Packs 16 50 36
Max Pcs. 128 400 288
Min Packs 12 36 28
Min Pcs. 96 288 224
# of Packs # of Pcs. # of Pcs. # of Pcs.
50 400
48 384
46 368
44 352
42 336
40 320
38 304
36 288 28834 272 272
32 256 256
30 240 240
28 224 224
26 208 208
24 192 192
22 176 176
20 160 160
18 144 144
16 128 128 128
14 112 112 112
12 96 96 96
10 80 80 80
8 64 64 64
6 48 48 48
4 32 32 32
2 16 16 16
Model ACM 138 ACM 251 ACM 031
D-817 Finished Goods Buffer
Updated by, date & time:
Inventory LevelsInventory Levels
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SEMAINE :
130 pice tombe
140 pice d'essai mthodes
150pice d'essai qualit
160 mlange pices / obsoltes
170 avarie de transport / stock
180 pice casse au montage
324 diamtre intrieur tles NC
326 tle dcale sur stator bobin
331 scrap fil cras
332 scrap fil crois
333 scrap fil court
334 scrap fil coup
335 scrap masse stator
336 scrap rsistance stator
337 torsadage NC
338 court circuit bobine
339 scrap surge
TOTAL SCRAP 60 38 18
cause
L M M TOTALJ V S D
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Pareto Analysis of Top Problems Manufacturign Cell: Week Ending:
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1
1 2 3 4 5 6 7 8 9 10 11
1 Handling damage 5 Paint Defects 9 Rust
2 Bad nuts/threads 6 Defective welds 10 Cracking
3 Manpower Shortage 7 Misformed 11 Lamination
4 Equipment Down 8 Old level parts 12 Setup scrap
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Daily Production Report
Date: Work Centre / Part #:
Time Schedule Actual Variance Reason / Time Lost
6:30-7:30 85 84 -1
7:30-8:30 85 85 0
8:30-9:30 65 63 -2
9:30-10:30 85 85 0
10:30-11:30 85 85 0
12:00-1:00 42 39 -3
1:00-2:00
2:00-3:00
Totals 447 441 -6
Team Leader Report:
TOP 5 PRODUCTION PROBLEMS:
1.
2.
3.
4.
5.
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Daily Production Report
Date: Work Centre / Part #:
Time OPTIMUM Schedule Actual Variance Reason / Time Lost
6:30-7:30 100 85 84 -1
7:30-8:30 100 85 85 0
8:30-9:30 80 65 63 -2
9:30-10:30 100 85 85 0
10:30-11:30 100 85 85 0
12:00-1:00 50 42 39 -3
1:00-2:00
2:00-3:00
Totals 447 441 -6
Maximum possible number to produce
under perfect conditions
Possible number to produce under
current conditions (today @ 85%)
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PARTS/OPERATOR/100 HRS (Daily)
GOAL = ______ MONTH________ YEAR_____ DEPT.(AREA) _______
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DAY X 100
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Weekly Lost Time Chart Manufacturign Cell: Week Ending:
Minutes
480
460
440
420
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380
360
340
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180
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120
100
80
60
40
20
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
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Month Daily Production Results - Line Shift
900
890
880
870
860
850
840 830
820
P 810a 800r 790t 780Targets 770
760
750
e 740
r 730720
H 710o 700u 690r 680
670
660 x
650
640 x
630
620
610
600
590
580
570
560
550 N/W N/W
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29
Day of the Month
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Production Lost Time Chart Part #: Month:
Time (Minutes) Week 1 Week 2 Week 3 Week 4 Monthly Total600
580
560
540520
500
480
460
440
420
400
380
360
340
320
300
280
260
240
220
200
180
160
140
120
100
80
60
4020
0 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7
Reasons for Lost Time: 2. Welder down 5.
1. parts shortage 3. Manpower shortage 6.
4. 7.
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Weekly Attendance Tracking
Monday Tuesday Wednesday Thursday Friday Saturday Sunday
A
ShiftPeople Required to Run 24 24 24 24 24 12 -
Actual Present 21 22 24 24 23 12
Call In/No Show -3 -2 0 0 -1 0
B
ShiftPeople Required to Run 18 18 18 18 18 5 -
Actual Present 17 16 18 18 18 4
Call In/No Show -1 -2 0 0 0 -1
C
ShiftPeople Required to Run 12 12 12 12 12 0 0
Actual Present 10 12 10 11 12 0
Call In/No Show -2 0 -2 -1 0 0
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Lean Transformation SolutionsLean Transformation Solutions
Marek PiatkowskiMarek Piatkowski
F.S.PF.S.P. Consulting Inc.. Consulting Inc.
VM: 416VM: 416--235235--26312631
Cell: 248Cell: 248--207207--04160416
[email protected]@rogers.com
www.TWIwww.TWI--Network.comNetwork.com
mailto:[email protected]:[email protected]://www.twi/http://www.twi/http://www.twi/http://www.twi/mailto:[email protected]:[email protected]