ssi sustainable solutions international, llc developers of spm ™ preparing the workplace for the...
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SSI
Sustainable Solutions International, LLCSustainable Solutions International, LLCDevelopers of SPMDevelopers of SPM™™
Preparing the Workplace forPreparing the Workplace for the 21the 21stst Century! Century!
Preparing the Workplace forPreparing the Workplace for the 21the 21stst Century! Century!
John Collins, CPIM John Collins, CPIM Mark Fiquett, CPIM, CIRMMark Fiquett, CPIM, CIRM
205-492-2188 205-492-2188 256-454-0912 256-454-0912
[email protected]@ssi-spm.com [email protected] [email protected]
www.ssi-spm.comwww.ssi-spm.com
a 21a 21stst Century Work place is Century Work place is A Synchronous Flow A Synchronous Flow
OrganizationOrganization
Are you there?Are you there?
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What’s A Synchronous Flow What’s A Synchronous Flow Organization?Organization?
Incorporates the benefits of Lean thinking, Six Incorporates the benefits of Lean thinking, Six Sigma philosophies, Work Force Sigma philosophies, Work Force empowerment, and ISO discipline.empowerment, and ISO discipline.
Benefits from having common goals and Benefits from having common goals and focuses shared by all employees.focuses shared by all employees.
Leverages those benefits in the market to Leverages those benefits in the market to create a competitive advantagecreate a competitive advantage
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5 key areas of a Synchronous 5 key areas of a Synchronous Flow OrganizationFlow Organization
1.1. Manufacturing FlowManufacturing Flow– Order receipt and processingOrder receipt and processing– Shop floorShop floor
2.2. OrganizationOrganization– Work force development Work force development – LeadershipLeadership– Performance Appraisals and CompensationPerformance Appraisals and Compensation– CommunicationCommunication
3.3. Continuous ImprovementContinuous Improvement– Customer Feedback, Safety, Process Action, Stretch TargetsCustomer Feedback, Safety, Process Action, Stretch Targets
4.4. MetricsMetrics– Actual versus TargetsActual versus Targets– Sales/marketing and financial aligned with operations Sales/marketing and financial aligned with operations
5.5. Global Supply ChainGlobal Supply Chain Flow -based master schedulingFlow -based master scheduling– Inventory managementInventory management– Supplier alliancesSupplier alliances– Capacity planningCapacity planning
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Manufacturing FlowManufacturing Flow1. Does material flow one way throughout the plant?2. Is the manufacturing process designed to have
operators touch material only one time?3. Are production areas aligned to end-customer
products?4. Are work centers designed to meet daily customer
requirements?5. Is product passed between operations one piece at a
time?6. Is the flow of production visible and understandable?7. Do operators flex between work centers?8. Is mfg. synchronization greater than 75%?
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OrganizationOrganization1. Are flow path leaders held accountable for end-
product performance results?2. Are cross-functional teams used on the flow path?3. Are the roles/responsibilities for all team members
defined and documented?4. Do operators know all steps in the flow process for
their areas?5. Are support roles clearly defined and involved in flow
path efforts?6. Is there a formal two-way communication process?7. Is management conducting performance appraisals
based on flow performance?8. Is compensation linked to performance?
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Continuous ImprovementContinuous Improvement1. Are changeover times on bottleneck resources less
than 10 minutes?2. Is there a formal continuous improvement program?3. Is response time less than 15 minutes for defects found
in the production process?4. Do team members have the authority to stop the flow
path when defects are discovered?5. Is the company philosophy “Everything has a place
and everything in its place”?6. Are stretch goals included in metrics?7. Are work instructions and product quality
specifications visible at all work areas?8. Are timetables posted for preventative maintenance or
continuous improvement efforts?
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MetricsMetrics
1. Are performance measures visible and current on the flow path?
2. Are updated charts on productivity, quality, safety, and problem solving visible to all teams?
3. Is performance reviewed daily by flow path teams?4. Is schedule adherence 100% on time?5. Are manufacturing cycle times less than one day?6. Is the flow path targeted performance continually
improving?7. Do flow path work center operators own and report
their performance data?8. Are performance metrics linked to financial metrics?
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Global Supply ChainGlobal Supply Chain1. Do flow paths build to customer demand?2. Is material pulled between stations?3. Does the shop floor produce to a daily build
schedule?4. Is the material replenished to an A,B,C segregation?5. Are shop floor operations rules documented and
understood?6. Are firm planning cycle times less than one day?7. Is a supplier certification process, with
measurements, displayed?8. Does the daily build plan meet customer and
financial commitments?
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SynchronousProcess Management
A Holistic ViewA Holistic View
Sustainable Solutions International, LLC
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SPM – The Holistic SolutionSPM – The Holistic SolutionA disciplined process A disciplined process control systemcontrol systemA common sense A common sense approachapproachA visual system to A visual system to manage the execution of manage the execution of processes throughout the processes throughout the businessbusinessA team-based, high A team-based, high involvement approachinvolvement approachA systematic way to A systematic way to organize, prioritize, and organize, prioritize, and managemanage
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Manufacturing Flow Deliverables Manufacturing Flow Deliverables with SPMwith SPM::
1.Product grouping2.Process mapping3.Routing analysis4.Workload balancing5.Kanban sizing6.Cell layout7.Standard work8.Visual flow9.Defined, auditable processes (Answer Book)
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Organization Deliverables with Organization Deliverables with SPMSPM::
1.Product focused teams2.Flow path management3.Roles and responsibilities4.Focused leadership5.Training matrix6.Communication process7.K.S.F.I.T. appraisals 8.Audit process
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Continuous Improvement Deliverables Continuous Improvement Deliverables with SPMwith SPM::
1.Work instruction review 2.Visual controls3.Line stop rules4.Flow metrics 5.Process action feedback system6.Stretch goals
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Metrics Deliverables with SPM:Metrics Deliverables with SPM:
1.On time delivery2.Process lead time3.Actual versus targeted costs4.First pass yield5.Inventory turns6.Mfg. cycle time7.Cash-to-Cash8.Productivity9.Customer linkage
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Global Supply Chain Global Supply Chain Deliverables with SPM:Deliverables with SPM:
1.Forward plan2.Mix modeling3.Level loading4.Daily financial and sales review of
loading plan5.Workable work6.Kanban pull signals7.ABC parts handling8.Customer/supplier alignment9.Operational rules
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Synchronous Flow Organizational Structure
Focused Leadership
Process Sequencing & Supplier
Linkage
Sustainability
Synchronous Process Management
Sustainable and Profitable
Operational Strategies require
all three!
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Make management commitment the first Make management commitment the first prioritypriorityProvide Provide EVERYONEEVERYONE with clear with clear expectations and the ability to meet those expectations and the ability to meet those expectationsexpectationsEnsure more involvement to achieve better Ensure more involvement to achieve better ownershipownershipMove fast, get results quicklyMove fast, get results quicklyBurn the camp (New mgt. roles to go with Burn the camp (New mgt. roles to go with the “new” focus)the “new” focus)
KeyKey Characteristics of Characteristics of SustainabilitySustainability
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Sustainable Solutions International, LLCSustainable Solutions International, LLCDevelopers of SPMDevelopers of SPM™™
Preparing the Workplace forPreparing the Workplace for the 21the 21stst Century! Century!
Preparing the Workplace forPreparing the Workplace for the 21the 21stst Century! Century!
John Collins, CPIM John Collins, CPIM Mark Fiquett, CPIM, Mark Fiquett, CPIM, CIRMCIRM
205-492-2188 205-492-2188 256-454-0912 256-454-0912
[email protected]@ssi-spm.com [email protected]@ssi-spm.com
www.ssi-www.ssi-spm.comspm.com