Fundamentals of Daily Shop Floor Management : A Guide for Manufacturing Optimization and Excellence (Paperback)

Fundamentals of Daily Shop Floor Management: A Guide for Manufacturing Optimization and Excellence Table of Contents: Preface Figure P.1: Steps to Operational Excellence Figure P.2: Daily Shop Floor Management Roadmap Reference Acknowledgment About the Author Introduction Overview Book Contents Part 1 - Shop Floor Foundation Part 2 - Shop Floor Fundamentals Part 3 - Shop Floor Management Part 4 - Shop Floor Improvement Part 5 - Shop Floor - Next Generation The Journey to Manufacturing Excellence Daily Shop Floor Management Essential Practices of Shop Floor Management Figure I.1: Principles and Practices of Daily Shop Floor Management Summary Side Bar: 8 Steps for Improving Shop Floor Performance Key Points A Note about Supply Chain Management (SCM) Manufacturing Supply Chain Management Administration Production Distribution Figure I.2: Key Supply Chain Functions Figure I.3: Supply Chain Management (SCM) Activities Figure I.4: Production Activities Sources Part 1 - Shop Floor Foundation Overview Figure 1.0.1: The Fundamental Elements of DSFM 1.1 Organizational Culture) Introduction Lean Mindset and Culture Key Points ? Culture Organizational Commitment Key Points - Commitment Organizational Alignment Key Points Side Bar: A Multicultural World Side Bar: Influencing Commitment Source 1.2 Organizational Structure Overview Figure 1.0.1A: Fundamental Elements of Daily Shop Floor Management Figure 1.2.1: Elements of Organizational Structure Organizational Framework Business Strategy Guiding Principles Routine Practices Shop Floor Management Planning Manufacturing Operations Manual (MOM) Side Bar: A Manufacturing Management System Guidelines, Procedures & Standards Shop Floor System Execution Standard Work Routines Figure 1.2.2 Operating Instructions Shop Floor System Monitoring Figure 1.2.3: System Monitoring Practices Key Process Indicators (KPI) Visual Controls Gemba Walks Performance Reviews Layered Process Audits Process Control Deviation Management Action Item List Structured Problem Solving Total Productive Maintenance Productivity Improvement Key Points Side Bar: Shop Floor Expectations 1.3 Operational Discipline Overview Figure 1.0.1B: Fundamental Elements of Daily Shop Floor Management Sustainable Discipline Improving Operational Discipline How to Maintain Operational Discipline Side Bar: Discipline Matters Key Points Sources 　 　 1.4 Employee Accountability Overview Figure 1.0.1C: Fundamental Elements of Daily Shop Floor Management Corporate Accountability Employee Accountability Side Bar: Ways to Enhance Employee Accountability Peer Accountability Shop Floor Accountability Setting Employee Expectations Employee Feedback Employee Empowerment Rewards and Consequences Treat People with Respect Communication Strategy Alignment Case Study: Are you a Management Tool or Empowered? Accountability vs. Micro-management Attitude, Behavior and Accountability Commitment and Accountability Key Points: Side Bar: Personal Accountability Part 2 - Shop Floor Fundamentals Overview Figure 2.0.1 Fundamentals of Shop Floor Management 2.1 Standardization Introduction Figure 2.1.1: Shop Floor Control and Improvement Workplace Cleanliness and Organization (5S) Procedures and Standard Work Instructions (SWI) Figure 2.1.2: Standard Work Instruction (SWI) Standard Operation Sheet (SOS) Figure 2.1.3: Standard Operation Sheet (SOS) Work Place Design Key Points 2.2 Shop Floor Data and Information Measurement Data Figure 2.2.1 Typical Manufacturing Metrics Key Process Indicators Figure 2.2.2: Input, Process, and Output indicators Figure 2.2.3: Types of Metrics Sidebar: Setting Performance Expectations Data Gathering Figure 2.2.4: Data Collection Plan Data Analysis Data Reporting Key Points 2.3 Data Visualization Overview Visual Controls for Process Management Figure 2.3.1: Visual Communication Elements Common Visual Control Displays Information or Communication Boards Figure 2.3.2: Information or Communication Board Example Figure 2.3.3: A Production Line Board Hourly Output Template Manpower Planning Boards Employee Cross-Training / Qualification Matrix Figure 2.3.4: Employee Qualification Matrix Andon Boards & Lights Tip: Chart Preparation Key Points 2.4 Shop Floor Communication Overview Figure 2.4.1: Five Shop Floor Communication Methods Machine to Machine (M2M) Communication Machine to Business (M2B) or Machine to Enterprise (M2E) Communication Shop Floor Communication Daily Meetings Figure 2.4.2: Daily Meeting Hierarchy Weekly Meetings Monthly Meetings Project Performance Reviews Gemba Walks Case Study: Gemba Walks in Action Mobile Devices Key Points 2.5 Shop Floor People People Overview Employee Empowerment Respect, Honesty, Trust Training & Development Side Bar: Developing People through Workshops Mentoring & Coaching Recognition & Reward Stakeholder Management Side Bar: Employee Satisfaction Key Points 2.6 Facilities Management Shop Floor Environment Technical Cleanliness Ergonomics ESD Utilities Key Points Part 3 - Shop Floor Management Overview Figure 3.0A: Fundamental Elements of Daily Shop Floor Management 3.1 Manufacturing System Execution Overview Figure 3.0B: Fundamental Elements of Daily Shop Floor Management Standard Work Routines Figure 3.1.1: Roles, Responsibilities, and Standard Work Routines Hierarchy Figure 3.1.2: Snapshot of Standard Work Routines. Preparing Standard Work Routines Key Points 3.2 Manufacturing System Monitoring Overview Figure 3.0C: Fundamental Elements of Daily Shop Floor Management Process Monitoring / Verification Figure 3.2.1: Shop Floor Monitoring Practices Go, See, Observe Gemba Walks Side Bar: The 10 Minute Gemba Walk Scrap Walks / Reviews Layered Process Audits Side Bar: Standard Process Audit Questions Performance Reviews Key Points 3.3 Manufacturing System Control Overview Figure 3.0D: Fundamental Elements of Daily Shop Floor Management Manufacturing System Control Figure 3.3.1: Manufacturing Practices and System Elements Process Control Figure 3.3.2: A View of Shop Floor Management Manufacturing System Integrity Standard Work Routines Deviation Management Figure 3.3.3: Deviation Management Methodology Structured Problem Solving Action Items Figure 3.3.4: Example of Action Item Format Decision Making Poka Yoke Jidoka Figure 3.3.5: Jidoka Process Flow Change Management Production Change Points Bottleneck Management Additional Manufacturing System Controls Figure 3.3.6: Manufacturing System Control Methods Key Points 3.4 Manpower Overview Figure 3.4.0 Engaging with People People Availability People Flexibility Workload Balancing Manufacturing Gages and Tools Employee Motivation Training & Experience Workplace Design & Ergonomic Working Conditions (environment) Autonomous Maintenance Labor Efficiency Employee Safety Side Bar: Covid-19 in the Workplace Key Points 3.5 Materials Overview Materials Requirements Planning (MRP) Material Deployment and Replenishment Milk Run Water Spider Material Handling and Storage Traceability Inventory Management Figure 3.5.1: Categories of Manufacturing Materials Health and safety Side Bar: Material Kitting Key Points 3.6 Manufacturing Equipment, Fixtures & Tooling Overview Equipment Optimization (Effectiveness, Reliability and Durability) Overall Equipment Effectiveness (OEE) Efficiency Losses (Big Six Losses) Figure 3.6.1: OEE Losses and Examples OEE Calculation OEE Improvement Cycle with PDCA Equipment Improvement Metrics - MTTR / MTBF Figure 3.6.2: Visual of Time to Repair and Time Between Failure Spare Parts Management Side Bar: Tips for Reducing Equipment Downtime - Good Operating Disciplines Equipment Reliability Equipment Calibration Measurement Systems Analysis Figure 3.6.3: Measurement System Analysis Overview Total Productive Maintenance (TPM) Autonomous Maintenance Systemic Maintenance Training & Qualification Asset Management Equipment Durability Key Points 3.7 Methods Overview PDCA 5S Method Deviation Management Side Bar: Investigating Abnormalities Change Management Structured Problem Solving Figure 3.7.1: Problem Solving Methods Just-in-Time Inventory Policy Deployment Figure 3.7.2: Policy Deployment Side Bar: Organizational Policy Single Minute Exchange of Die (SMED) Figure 3.7.3: Changeover Time Reduction Process Agile Manufacturing Side Bar: Negative Side to Company growth Summary Key Points 3.8 Environment Overview Building layout/design Ergonomics Safety Figure 3.8.1: Safe Workplace Lighting Temperature Ventilation Air Quality Air Current Noise Humidity Facility Space Case Study: The Value of Space Vibration Key Points Part 4 - Shop Floor Improvement Overview 4.1 Product & Process Development Overview Design for Manufacturing Figure 4.1.1: Design for Manufacturing Overview Design for Six Sigma Figure 4.1.2.: DFSS Methodology (DICOV) Design & Process FMEA Figure 4.1.3.: Failure Modes & Effects Analysis Key Points 4.2 Productivity Improvement Overview Figure 4.2.0: Process Maturity Incremental Improvement Sustainable Improvement Side Bar - Leveraging Organizational Knowledge Improvement Methods Quality Circles Figure 4.2.1 - Seven Basic Quality Tools Employee Idea Management Set-up and Changeover (SMED) Six Sigma DMAIC Figure 4.2.2: Six Sigma DMAIC Methodology Kata / PDCA Project Figure 4.2.3 The Five Toyota Kata Questions and Four Reflections Value Analysis Figure 4.2.4. Value Analysis Process Kaizen Events Figure 4.2.5: Kaizen Event Process Jishuken (Self-study) Workshops Side Bar: Jishuken Workshops Improvement Tools & Techniques Go, See, Observe, Understand and Confirm Side Bar: Tip for Effective Observation Workplace Design Process Mapping Six Thinking Hats Workload Balancing Figure 4.2.6: Workload Balancing - Before and After Production Leveling Figure 4.2.7: Production Leveling. Yamazumi Charts Figure 4.2.8: Yamazumi chart Buffer Management Best Practice Sharing Lessons Learned Key Points References 4.3 Agile Methods Agile Overview Application of Agile Practices Predictive, Iterative and Incremental Life Cycles Figure 4.3.1: Predictive Life Cycle Figure 4.3.2: Iterative Life Cycle Daily Stand-up meetings Retrospectives Co-location Side Bar: Agility Response Case Study: Manufacturing Agility Key Points 4.4 Shop Floor Optimization Overview Figure 4.4.0: Optimize Knowledgeable and Skilled People Cooperation and Collaboration Available and Reliable Equipment Materials Management Practices and Procedures Operator Movement Optimization Material Flow Optimization Environmental Optimization Optimization Methods, Tools and Techniques Process Characterization Design of Experiments Response Surface Analysis Process Flow Optimization Methods Value Stream Mapping / Design Figure 4.4.1 Value Stream Improvement Side Bar: Optimization Beyond the Shop Floor Constraint Management Spaghetti Diagram Figure 4.4.2 ? Spaghetti Diagram Example Lessons Learned Case Study: A Pitch for Lessons Learned Key Points 4.5 Manufacturing Excellence Overview Enterprise Alignment Organizational Structure Operational Discipline Employee Accountability Side Bar: Organize and Prioritize Agility Mindset Employee Development Process Control Continuous Improvement Side Bar: Welcome Visitors Technical Advancement Supplier Partnerships Lessons Learned Shop Floor Practices Summary Case Study: Rules of Engagement Key Points Part 5 - Next Generation Shop Floor Overview Industry 4.0 Expectations Digital Transformation Productivity Improvements that make a Difference Part 1 - Technical Innovations Collaborative Robots (Cobots) Figure 5.1: Cobot Robotic Process Automation (RPA) Automated Guided Vehicles (AGVs) Micro AGVs Smart Glasses Centralized (Automated) Inspection (AOI) Case Study: Visual Inspection with Artificial Intelligence Fixed Production Cell Autonomous (digital) Workforce Part 2 - Thinking Differently Big Data Side Bar: Improvement Projects Using AI Equipment Robustness (Reliability & Durability) Predictive Equipment Maintenance Figure 5.2: Evolution of Predictive Maintenance Spare Parts Management 3D Printing of Spare Parts Suitcase Tester Vendor Managed Inventory (VMI) Figure 5.3: Vendor Managed Inventory Machine Learning Modular Product Architecture Mobile Devices Gamification Environmental Sustainability Key Points Appendices Appendix 1 - Daily Shop Floor Management Checklist Appendix 2 - Manufacturing Operations Manual Appendix 3 - Standard Work Routines Appendix 4 - Tips for Shop Floor Monitoring Appendix 5 - SMED Workshop Appendix 6- Jishuken Workshop Outline Appendix 7 -Acronyms & Terms