The Lean Experience
Factory simulation - materials
Checklist – Factory simulation materials
•
Templates folder
•
Circuit boards – 120 (3 rounds X 15 orders X 2 sheets/order + 30% buffer + 5 sheets
for round 4)
•
7 packets of dots – 2 Green, 2 Blue, 2 Red, 1 White – 1,000 each colour (3 rounds X
15 orders X 50 dots +30% buffer + 30 for round 4)/3 colours
•
Box – 4 scissors, 5 stopwatches, 1 caliper, discs
•
Dice – 2 customer, 20 standard dice
•
Changeover timers
•
Maintenance toolboxes (2)
•
Paper cutter
•
DVD’s – Creating a Lean Culture and What Lean Means
Checklist – round 1
Customer
•
Label
•
Work instruction
•
2 dice
•
Stopwatch
•
Customer order log sheet
Production Control
•
Label
•
Work instruction
•
Post-it notes
•
Prod Cont order log sheet
Warehouse
•
Label
•
Work instruction
•
Circuit boards
•
Nano dots
Fusing
•
Label
•
Work instruction
•
2 dice
•
2 orange changeover timers
Laser Cutting
•
Label
•
Work instruction
•
2 green scissors
•
2 dice
•
2 black changeover timers
Sorting
•
Label
•
Work instruction
Shipping
•
Label
•
Work instruction
Maintenance
•
Label
•
Work instruction
•
Maintenance toolbox
•
2 stopwatches
•
Maintenance log sheet
Quality
•
Label
•
Work instruction
•
Quality log sheet
Continuous Improvement
•
Label
•
Work instruction
•
2 stopwatches
•
CI observation sheet
Material handling
•
Label
•
Work instruction
Plant manager
•
Label
•
Work instruction
Checklist – round 3
Customer
•
Work instruction
•
2 dice
•
Stopwatch
•
Customer order log sheet
Production Control
•
Work instruction
•
WIP storage labels (3)
•
FG storage labels (3)
Warehouse
•
Work instruction
•
Circuit boards
•
Nano dots
•
POUS labels (4)
Fusing
•
Work instruction
Laser Cutting
•
Work instruction
•
2 blue scissors
Shipping
•
Work instruction
Maintenance
•
Work instruction
•
Maintenance toolbox
•
2 stopwatches
•
Maintenance log sheet
Quality
•
Work instruction
•
Quality log sheet
Continuous Improvement
•
Work instruction
•
2 stopwatches
•
CI observation sheet
Material handling
•
Work instruction
Plant manager
•
Work instruction
Checklist – round 4
Customer
•
Work instruction
•
2 dice
•
Stopwatch
•
Customer order log sheet
Production Control
•
Work instruction
•
FG storage labels (1)
Warehouse
•
Work instruction
•
Circuit boards
•
Nano dots
•
POUS labels (4)
Fusing
•
Work instruction
Laser Cutting
•
Work instruction
•
2 blue scissors
Shipping
•
Work instruction
Maintenance
•
Work instruction
•
Maintenance toolbox
•
2 stopwatches
•
Maintenance log sheet
Quality
•
Work instruction
•
Quality log sheet
Continuous Improvement
•
Work instruction
•
2 stopwatches
•
CI observation sheet
Material handling
•
Work instruction
Plant manager
•
Work instruction
Template checklist – round 1
Role
Std work
Log sheet
Customer
1
1
Warehouse
1
Production Control
1
Fusers
2
Laser Cutters
2
Sorters
2
Material handlers
2
Shipping
1
Maintenance
1
1
Quality
1
1
Continuous Improv
1
1
Plant Manager
1
1
Other
Template checklist – round 3
Role
Std work
Log sheet
Other
Customer
Same R1
1
Warehouse
1
POUS – 2 Circuit boards, 2 Nano dot
Production Control
1
2 WIP storage, 2 FG storage
Fusers
2
Fusing error proofing templates
Laser Cutters
2
Material handlers
1
Shipping
1
Maintenance
1
1
Quality
1
1
Continuous Improv
1
1
Plant Manager
1
Quality standards
Template checklist – round 4
Role
Std work
Log sheet
Other
Customer
Same R1
1
Warehouse
1
POUS – 2 Circuit boards, 2 Nano dot
Production Control
1
1 FG storage
Fusers
2
Laser Cutters
2
Material handlers
1
Shipping
1
Maintenance
1
1
Quality
Same R3
1
Continuous Improv
Same R3
1
Plant Manager
Same R3
Quality standards
Data sheet checklist
Title
Quantity
Customer order log sheet
4
Prod Cont order log sheet
4
Maintenance log sheet
4
Quality log sheet
4
CI observation sheet
4
Customer
Customer work instructions
1 of 1
Purpose
•
As the customer, you will place an order every minute for 15 minutes.
•
You expect “on time” delivery (note 1 below) and 100% quality (note 2).
Materials
•
A stopwatch to time the orders & delivery.
•
2 large dice to roll for orders + 6 coloured dots and 6 white dots (refer notes 4 & 5).
•
Customer order log sheet to record the orders, delivery times and any quality issues.
Procedures
Orders
1. Announce the start of the round.
2. Roll the 2 dice to determine the order (note 3 & 4)
3. Tell the Production Controller the order
4. Record the time, type & quantity on the “Order log sheet”
5. Repeat steps 2-4 exactly one minute apart until the round is complete one minute after the 15 th order.
6. Announce the end of the round.
Deliveries
1. When a delivery is received, check for the correct delivery (note 1) and quality (note 2). If all is correct, record the
time of delivery and calculate the lead time. If the delivery or quality is not correct, reject the whole delivery and
record reasons on the “Order log sheet”.
2. For repeat delivery or quality problems, express your displeasure to the Production Control person. If this does not
work, elevate your concerns to the Plant Manager.
Notes
1. A delivery with the correct product type and quantity received within a minute of placing the order is considered “on
time”. Deliveries must be received in the sequence in which they were ordered. Deliveries received out of
sequence are to be rejected.
2. Good quality is a full nano dot with no visible damage. If any damaged or missing (blank square) nano dots are
found, the whole order is rejected.
3. Do not communicate these requirements to your supplier unless directly asked.
4. Product type die – coloured dots on the die indicate the product type. Change the product mix for each round, e.g.
R1 2G2B2R, R2 1G3B2R, R3 2G1B3R, R4 3G2B1R (each combination must have at least one of the three product
colours).
5. Quantity die – use white dots with the following numbers for each round R1 – 4X50, 1X75, 1X25; R2 – same as
round 1; R3 – 40, 45, 50, 50, 55, 60; R4 – Quantity dice not used.
Customer order log sheet
No.
Type
E,CO2,
H2O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Qty
Order
time
Delivery
time
Round No. ______
Lead time Delivery or quality
(Del – Ord) issues
Raw materials
warehouse
Warehouse work instructions
Round 1
1 of 1
Purpose
•
As the warehouse store person, you store the raw materials and fill orders from Production Control.
Materials
•
Circuit boards
•
Nano dots – 3 types: Green CO2, Blue H2O, Red E.
Procedures
1. Receive the customer order from Production Control.
2. Pick the required raw materials for the order.
3. Contact the Material Handler and ask them to deliver the raw materials to the start of production (Fusing).
Notes
1. Your boss is Production Control. Do not release raw materials from the warehouse without a customer order from
Production Control.
2. You provide excellent service to Future Solutions Enterprise and carry inventory a large inventory of raw materials to
make sure production never runs out.
Warehouse work instructions
Round 3
1 of 1
Purpose
•
As the warehouse store person, you store the raw materials and fill orders from Production Control.
•
To reduce wasted motion by operators, you have implemented point of use storage at the Fusing operation for nano
dots and circuit boards.
•
As circuit boards take up a lot of space, you have determined that you will keep only 5 at the Fusers’ workstation.
These will be replenished as used.
•
To reduce waste in the Cutting operation, the supplier of the circuit boards has been requested to supply the grid
area only, without the waste around the edges.
Materials
•
Circuit boards
•
Nano dots – 3 types: Green CO2, Blue H2O, Red E.
•
Paper cutter.
•
2 laminated point of use storage locators for circuit boards.
•
2 laminated point of use storage locators for nano dots
•
Masking tape.
Procedures
Set up prior to start of round
1. Cut out the grids on the circuit boards and dispose of the waste around the edges so that only the usable grid is
supplied.
2. Layout laminated sheets for point of use storage locations at the Fusers’ workstation (secure with tape).
3. Fill the point of use storage locations with materials.
During the round
1. Prepare more cut out circuit boards as required.
2. Monitor usage of the circuit boards and replenish as required (keeping the inventory at point of use to 5).
3. Work with the material handler to make sure the Fusers do not run out of raw materials.
Notes
1. The material handler will deliver the circuit boards to the Fusers.
Fuser 1 - storage area for circuit boards (R3)
Max 5
Fuser 1 - storage area for nano dots
Fuser 2 - storage area for circuit boards (R3)
Max 5
Fuser 2 - storage area for nano dots
Warehouse work instructions
Round 4
1 of 1
Purpose
•
As the warehouse store person, you store the raw materials and fill orders from Production Control.
•
The point of use storage and replenishment system is the same as used in round 3.
•
The Fusing and Laser Cutting processes have been improved to incorporate continuous flow. The supplier of the
circuit boards has made a change to supply these in single strips of 10.
Materials
•
Circuit boards
•
Nano dots – 3 types: Green CO2, Blue H2O, Red E.
•
Paper cutter.
•
2 laminated point of use storage locators for circuit boards.
•
2 laminated point of use storage locators for nano dots (same as round 3).
•
Masking tape.
Procedures
Set up prior to start of round
1. Cut up 20 sheets into single strips of 10 squares using the paper cutter.
2. Provide the boxes of nano dots and 10 strips to the Fusers (5 each).
During the round
1. Monitor usage of the strips and replenish as required (keeping the inventory at point of use to 5 per Fuser).
2. Work with the material handler to make sure the Fusers do not run out of raw materials.
Notes
1. The material handler will deliver the circuit boards to the Fusers.
Fuser 1 - storage area for circuit boards (R4)
Max 1 strip
Max 1 strip
Max 1 strip
Max 1 strip
Max 1 strip
Fuser 2 - storage area for circuit boards (R4)
Max 1 strip
Max 1 strip
Max 1 strip
Max 1 strip
Max 1 strip
Production
Controller
Prod. Cont. order log sheet
No.
Type
E,CO2,H2O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Qty
Round No. ______
Delivery or quality issues
Production controller work instructions
Round 1
1 of 1
Purpose
•
As the Production Controller, you will schedule production of orders through the factory.
•
You are also responsible for ordering raw materials from the supplier and delivering them to production.
Materials
•
Post-it notes and pen for recording orders.
•
Prod. Cont. order log sheet.
Procedures
1. Receive the order from the customer.
2. Record the order (Order no, type, quantity) on a post it note and the Prod Cont order log sheet.
3. Give the order to the warehouse to deliver raw materials required to start of production.
4. Monitor the progress of the order to make sure the order remains with the work as it progress through the factory so
that the complete order is delivered to the customer in the correct sequence.
5. Record details on the Prod Cont order log sheet.
Notes
1. The warehouse store person and the material handler work for you.
2. Production control delivers and monitors orders but does not move materials (ie circuit boards, nano dots or work in
progress). This is the job of the material handler.
3. Production control is the first point of contact for the customer for delivery or quality issues. Work with the
production people and support people to help resolve any issues.
Production controller work instructions
Round 3
1 of 1
Purpose
•
As the Production Controller, you have worked with the production people to establish kanban pull systems.
•
To ensure supply, you have installed point of use storage for raw materials and a kanban system with the Supplier.
Materials
•
Laminated product storage locations: 3 between Fusing and Laser Cutting; 3 finished product storage
Procedures
Set up of kanban systems
1. Prior to the start of round 3, set up the kanban system by placing the WIP storage templates between Fusing and
Cutting and the FG storage template after Laser Cutting.
During the round
•
Monitor the inventory levels.
•
No need to record production orders.
WIP storage after Fusing (R3)
Max 2
WIP storage after Fusing (R3)
Max 2
WIP storage after Fusing (R3)
Max 2
Finished goods storage (R3)
FIFO flow
55
45
35
25
15
5
60
50
40
30
20
10
60
50
40
30
20
10
5 per square
Finished goods storage (R3)
FIFO flow
55
45
35
25
15
5
60
50
40
30
20
10
60
50
40
30
20
10
5 per square
Finished goods storage (R3)
FIFO flow
55
45
35
25
15
5
60
50
40
30
20
10
60
50
40
30
20
10
5 per square
Production controller work instructions
Round 4
1 of 1
Purpose
•
As the Production Controller, you have worked with the production people to establish kanban pull systems.
•
To ensure supply, you have installed point of use storage for raw materials and a kanban system with the Supplier.
Materials
•
1 laminated finished product storage location.
Procedures
Set up of kanban systems
1. Prior to the start of round 4, set up the kanban system by placing the FG storage template after Laser Cutting.
During the round
•
Monitor the inventory levels.
•
No need to record production orders.
Finished goods storage (R4)
Max 1
Max 1
Max 1
Max 1
Max 1
Max 1
Fusers
Fusers’ work instructions
Round 1
1 of 1
Purpose
•
To fuse the nano dots to the circuit boards
Materials
•
Circuit boards & nano dots
•
2 orange changeover timers
•
2 downtime dice
Procedures
1. The circuit boards and nano dots required for each order are delivered by the material handlers.
2. Place the nano dots on the circuit boards in the configuration shown below.
3. When the order is complete, notify the material handler to collect the order.
4. When changing between different products, turn over the orange changeover timer, wait for the changeover to take
place (when the sand runs out), then proceed with production.
5. When every 3rd order is received, before starting production, roll the downtime dice and take the action below
depending on what number is rolled:
1. Equipment failure – call maintenance and tell them you need a 1/8” X 3/4” nut & bolt. Wait till received.
2. You are concerned about running out of parts in the warehouse. Go and question the store person.
3. Equipment failure – call maintenance and tell them you need a 3/16” X 1/2” nut & bolt. Wait till received.
4. You are concerned about what you will have to run for the rest of the round. Go and question Prod. Control
5. Equipment failure – call maintenance and tell them you need a 1/4” lock washer. Wait till received.
6. Go and ask the Plant manager how the current round of wage bargaining is going.
X
X
E
X
X
X
X
X
X
X
X
CO2
X
X
X
X X
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X X
X X
X
X X
Notes
1. Prepare the orders in the sequence they are received.
X X
X
H 2O
X X
X X
X X
X
X
X X
X
X
X X
X X
X
X
X
X X
X
X
X
X
X
X
X X
X
X
X
X X
Fusers’ work instructions
Round 3
AREA
Fusing
STD #
2035
Job Title
Fuser
1 of 1
STANDARD WORK GUIDE
Approved by
J Lee
Revision
Round 3
Date
14/9/08
1
2
3
4
1. Critical
Walk
#
Work
Time
Process description
Determine next product to build
based on replenishment of product
taken from WIP storage.
Pick up the relevant product
template and insert a blank circuit
board.
Place template on the table, pick up
the nano dot dispenser matching the
colour of the templante and fuse the
nano dots to the circuit board
through the holes in the template.
When all dots are applied, remove
circuit board from template and
place the completed product in the
appropriate WIP storage location.
2. Safety 2. Look
Key points
Coordinate production
with the other fuser so as
not overproduce – max 2.
Slide the circuit board to
the top right corner of the
template and line up the
holes with the grid.
Hold the nano dot
dispenser close to the
template and use thumb to
draw out the nano dot.
Be careful to place the
dots inside the grid.
Check template to ensure
no dots are on the lines.
Visual aides
Fusers’ work instructions
Round 4
AREA
Fusing
STD #
2035
Job Title
Fuser
1 of 1
STANDARD WORK GUIDE
Approved by
J Lee
Revision
Round 4
Date
14/9/08
1
2
1. Critical
Walk
#
Work
Time
Process description
Determine next product to build
based on replenishment of product
taken from FG storage.
Pick up the relevant nano dot
dispenser and fuse a nano dot to the
circuit board strip being held by the
Laser Cutter.
2. Safety 2. Look
Key points
Coordinate production
with the Laser Cutter so
as not overproduce –
maximum of 2 per
product.
Use a thumb to draw out
the nano dot.
Be careful to place the
dots inside the grid.
Visual aides
Laser
Cutters
Laser Cutters’ work instructions
Round 1
1 of 1
Purpose
•
To laser cut out the individual squares.
Materials
•
Circuit boards with nano dots
•
Laser scissors
•
2 black changeover timers
•
2 downtime dice
Procedures
1. The circuit boards with nano dots required for each order are delivered by the material handlers.
2. Cut the circuit boards into individual squares.
3. When the order is complete, notify the material handler to collect the order.
4. When changing between different products, turn over the black changeover timer, wait for the changeover to take
place (when the sand runs out), then proceed with production.
5. When every 5th order is received, before starting production, roll the downtime dice and take the action below
depending on what number is rolled:
1. Equipment failure – call maintenance and tell them you need a 1/4” X 3/4” nut & bolt. Wait till received.
2. You are concerned about running out of parts in the warehouse. Go and question the store person.
3. Equipment failure – call maintenance and tell them you need a 3/16” X 3/4” nut & bolt. Wait till received.
4. You are concerned about what you will have to run for the rest of the round. Go and question Prod. Control
5. Equipment failure – call maintenance and tell them you need a 1/4” flat washer. Wait till received.
6. Go and ask the Plant manager how the current round of wage bargaining is going.
Notes
1. Be careful – the laser scissors are sharp!
2. Prepare the orders in the sequence they are received.
Laser Cutters’ work instructions
Round 3
AREA
Laser Cutting
STD #
2035
Job Title
Laser Cutter
1 of 1
STANDARD WORK GUIDE
Approved by
J Lee
Revision
Round 3
Date
14/9/08
Walk
#
Work
Time
Process description
1
Determine next product to build
based on replenishment of product
taken from FG storage.
2
Pick up the circuit board from the
WIP storage location and cut the
board into strips along the longest
side.
3
Turn one pile of strips 180º and pick
up both piles stacking them on top.
4
Cut the squares into two piles –
blank squares in the waste pile and
the nano dot squares onto an empty
space on the FG storage location.
2. Safety 2. Look
1. Critical
Key points
Coordinate production
with the other Laser Cutter
so as not overproduce –
maximum of 60 per
product.
Cut the strips into 2 piles
with same pattern of the
nano dots.
Be careful while cutting –
the Lasers are sharp.
This will result in all strips
having the nano dots in
the same pattern.
Make sure the stack is
lined up to cut. There will
be 5 nano dot squares per
storage location.
Visual aides
Laser Cutters’ work instructions
Round 4
AREA
Laser Cutting
STD #
2035
Job Title
Laser Cutter
1 of 1
STANDARD WORK GUIDE
Approved by
J Lee
Revision
Round 4
Date
14/9/08
Walk
#
Work
Time
Process description
1
Determine next product to build
based on replenishment of product
taken from FG storage.
2
Pick up the circuit board from the
WIP storage location and hold it for
the fuser to apply a nano dot.
Cut the nano dot squares onto an
empty space on the FG storage
location.
3
1. Critical
2. Safety
2. Look
Key points
Coordinate production
with the other Laser Cutter
so as not overproduce –
maximum of 2 per
product.
Be careful while
cutting – the
Lasers are sharp.
Visual aides
Sorters
Sorters’ work instructions
Round 1
Purpose
•
To sort the final product from the waste material.
•
To inspect the final product to ensure it is good quality.
Materials
•
Nano dot squares and blank squares.
Procedures
1. The nano dot squares and blank squares for each order are delivered by the material handlers.
2. Sort the squares into two piles – ones with nano dots and blanks.
3. Discard the blanks.
4. Inspect the ones with nano dots to ensure good quality.
5. When the order is complete, notify the material handler to collect the order.
Notes
1. Prepare the orders in the sequence they are received.
1 of 1
Sorters’ work instructions
Round 3
1 of 1
Material
Handlers
Material handlers’ work instructions 1
Round 1
Purpose
•
To move material through the factory
Procedures
1. Transport materials (steps 2 – 6) as directed by staff.
2. Collect orders from production control and deliver to the warehouse.
3. Collect circuit boards and nano dots from the warehouse and deliver to the Fusing workstation.
4. Collect circuit boards with nano dots from the Fusing workstation to the Laser Cutting workstation.
5. Collect the cut squares from the Laser Cutting workstation to the Sorting workstation.
6. Collect the finished nano dot squares from the Sorting Station to the Shipping location.
Notes
1. Only material handlers are to move material through the factory.
2. Priorities are set by who screams the loudest.
1 of 1
Material handlers’ work instructions 2
Round 1
Purpose
•
To move material through the factory
Procedures
1. Transport materials (steps 2 – 6) as directed by staff.
2. Collect orders from production control and deliver to the warehouse.
3. Collect circuit boards and nano dots from the warehouse and deliver to the Fusing workstation.
4. Collect circuit boards with nano dots from the Fusing workstation to the Laser Cutting workstation.
5. Collect the cut squares from the Laser Cutting workstation to the Sorting workstation.
6. Collect the finished nano dot squares from the Sorting Station to the Shipping location.
Notes
1. Only material handlers are to move material through the factory.
2. Priorities are set by who screams the loudest.
1 of 1
Material handlers’ work instructions
Round 3 & 4
Purpose
•
To ensure that the Fusers do not run out of raw material.
Procedures
•
Work with the warehouse to replenish the point of use storage at the Fusing workstation.
1 of 1
Shipping
Shipping work instructions
Round 1
1 of 1
Purpose
•
To ship finished goods to the customer.
Procedures
1. Receive the finished products delivered by the material handler.
2. Check the finished products against the customer order to ensure that the product type, quantity and quality are
correct.
3. Notify Production control of any discrepancies in quantity or product type.
4. Notify Quality of any quality issues.
5. Once the order is correct, ship the product to the customer.
Shipping work instructions
Round 3
1 of 1
Purpose
•
To ship finished goods to the customer.
Procedures
1. When the customer announces the order, deliver the product by sweeping the correct quantity from the finished
product storage locations.
2. After each delivery, move any remaining products forward to maintain FIFO.
Shipping work instructions
Round 4
1 of 1
Purpose
•
To ship finished goods to the customer.
Procedures
1. When the customer announces the order, deliver the product by sweeping the correct quantity from the finished
product storage locations.
2. After each delivery, move any remaining products forward to maintain FIFO.
Maintenance
Maintenance log sheet
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Dept
Part
required
Total
downtime
(min)
Round No. ______
Comments
Maintenance work instructions
Round 1
1 of 1
Purpose
•
To fix equipment when problems occur.
Materials
•
Maintenance tool box.
•
A caliper to measure the bolts.
•
2 stopwatchs to measure downtime.
•
Maintenance log sheet.
Procedures
1. Stay in the maintenance workshop unless you receive a call from an operators when equipment is broken down.
2. When called to a breakdown, start the stopwatch and time total downtime (stop when the problem is fixed).
3. Find out from the operator what part is required to fix the equipment.
4. Return to the maintenance workshop and search through the tool box to find the part.
5. Measure the part to verify it is correct.
6. Return to the equipment and fix the equipment (refer note 2).
7. Record the details on the Maintenance log sheet
Notes
1. A 1/8” X 3/4” nut & bolt refers to the thread on the bolt that is 1/8” in diameter and 3/4” in length.
2. For this simulation, the equipment will be considered “fixed” when you show the operator the correct part.
Maintenance work instructions
Round 3
1 of 1
Purpose
•
Maintain equipment through a Preventative Maintenance program and react quickly to fix failures.
Materials
•
Maintenance tool box 5S.
•
2 stopwatchs to measure downtime.
•
Maintenance log sheet.
Procedures
1. You have applied 5S to you toolbox and made it mobile so you can take this to the operations rather than it being
kept in the maintenance workshop.
2. Use stopwatch to time downtime (same as round 1).
3. Record the details on the Maintenance log sheet
Maintenance work instructions
Round 4
1 of 1
Purpose
•
Develop operators to perform condition monitoring and minor PMs. Perform regular major PMs and quickly react to
fix breakdowns. Constant analysis of data to improve PM system.
Materials
•
Maintenance tool box 5S.
•
2 stopwatchs to measure downtime.
•
Maintenance log sheet.
Procedures
1. Congratulations – the improvements to the PM system and condition monitoring have resulted in equipment failures
being a rarity.
2. Record any downtime on the Maintenance log sheet.
Quality
Quality work instructions
Round 1
Purpose
•
As the Quality person, you job is to fix quality problems.
Materials
•
Quality log sheet
Procedures
1. During the round, monitor quality and address any customer concerns.
2. Record problems on the Quality log sheet.
Notes
1. Make any quality problems an “emotional” event.
1 of 1
Quality work instructions
Round 3 & 4
1 of 1
Purpose
•
As the Quality person, you have been working with production to proactively improve quality rather than the
continual fire fighting in previous rounds.
Materials
•
Quality log sheet
•
Visual quality standards
•
Error proofing templates for Fusing
Procedures
Set up
•
You have worked with the customer to develop visual quality standards.
•
Work with operators to make sure they are aware of the quality standards and are posted in the work areas.
•
You have developed error proofing templates to prevent incorrect placement of nano dots at the Fusing operation.
Work with the Fusing team to make sure they are able to use the templates correctly.
During the round
•
Monitor quality issues and work with the production team to resolve.
•
Record problems on the Quality log sheet.
Quality log sheet
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Dept
Product
Round No. ______
Qty
Comments
E – example quality product after Fusing operation

Nano dot
placed in
centre

Nano dot
touching
a line
CO2 – example quality product after Fusing operation

Nano dot
placed in
centre

Nano dot
touching
a line
H2O – example quality product after Fusing operation

Nano dot
placed in
centre

Nano dot
touching
a line
Quality board – finished product
Acceptable quality = no visible damage to the nano dot
Note: condition of the backing does not affect product quality


Cut
Folded
Scratched
Continuous
Improvement
CI observation sheet
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
Operation
Observation
Round No. ______
Type of
waste
Time
(sec)
CI work instructions
Round 1
1 of 1
Purpose
•
As the Continuous Improvement coordinator, you job is to identify and implement process improvements.
Materials
•
CI observation sheet
Procedures
1. Use the CI observation sheet to document any problems you see during the round and any ideas for improvement.
2. At the end of the round, you will be asked for your observations and ideas.
CI work instructions
Round 3 & 4
1 of 1
Purpose
•
As the Continuous Improvement coordinator, you job is to develop the expertise of your people in process
improvement.
Materials
•
CI observation sheet
Procedures
•
You have worked with the production cells through kaizen events which have achieved many improvements. These
improvements have been incorporated in the Standard Work.
•
Use the CI observation sheet to document any problems you see during the round and any ideas for improvement.
•
At the end of the round, you will be asked for your observations and ideas.
Plant
Manager
Plant manager work instructions
Round 1
1 of 1
Purpose
•
As Plant Manager, the buck stops with you!
Procedures
1. Prior to the commencement of the round, you give the troops a motivational speech.
2. The theme of the speech is that we have spent a lot of money on the plant, we have a great process which is well
documented in the work instructions (developed by our fine engineers), and that we better make some money
otherwise all our jobs will be on the line.
3. During the round, look for trouble spots and give directions.
Notes
•
Play the “command & control” plant manager.
Plant manager work instructions
Round 3 & 4
1 of 1
Purpose
•
As Plant Manager, your job is to develop your people and provide leadership.
Procedures
•
Prior to the commencement of the round, you give the troops a motivational speech.
•
The theme of the speech is different from round 1. Focus on giving credit to the various teams that have improved
the operations and encouragement & incentive to meet customer requirements.
•
During the round, give encouragement to your team.