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Instructions for Lean VTC Brief 18 JUL 06 Rev 1

Instructions for Lean VTC Brief 18 JUL 06 Rev 1. Please be brief and focus on your report on the timekeeping event addressed in the 13 Sep 05 FMO letter. Fill in all metrics data. This includes a review slide for both the Material and IPE events.

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Instructions for Lean VTC Brief 18 JUL 06 Rev 1

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  1. Instructions for Lean VTC Brief18 JUL 06 Rev 1 • Please be brief and focus on your report on the timekeeping event addressed in the 13 Sep 05 FMO letter. • Fill in all metrics data. This includes a review slide for both the Material and IPE events. • Limit pictures to those that save 1000 words. • Request email briefs to me by COB 14 Jul 06. The “early bird” activity will be rewarded!! • Keep briefs under 5 Megs please. • Delete the first five slides of this template in your submitted brief.

  2. FY06 Lean Timekeeping VTC (13 Sep 05 Guidance Letter) (1) Report FMA unused capacity (hours) by department and reason for the first six months of FY06. (2) Report missing time by department for the first six months of FY06 (NEMAIS Report 700-2) (will be mostly milpers) (3) Report the top five overtime usage cost centers by shop/code. Report lost time, training time and leave for the same shops and codes (NEMAIS Report 900-6). (4) Report results of charge validation analysis conducted within and by each FMA. Determine the indicated validity of charges to a statistically significant sample of production jobs. (5) Identify the case study topic and report progress of planning.

  3. Charge ValidationAnalysis • Use the provided template (next two pages) in production department only • Collect data on two different days in two different weeks • Compare data to charges in the system • Determine charge validity

  4. Charge Validity Template • Purpose:FMO FY06 lean guidance letter requested a charge validation analysis to indicated validity of charges against production jobs. Accurate charging is important to support progressing systems and to support budget development based on return cost data retained. • Basis: A sampling plan has been developed for use by FMAs. The plan provides a means to determine with confidence whether timekeeping is accurate to a given acceptable quality level. This template supports a confidence level of 95% for an acceptable quality level of 4% defective. (An AQL of 4% implies that 4 incorrect timecards per 100 are accepted.) • Approach: • Determine the size of your available production workforce. • Determine the appropriate sample size. (For 501-1200 workers sample size is 80; 281-500 workers sample size is 50; 151-280 workers sample size is 32) • Observe and record the actual job being worked for each worker in the sample size for your FMA. • Compare the system charges for each worker sampled after charges have been posted to the system. If a charge is recorded for the job actually observed, the timecard is accepted. If the job observed is not charged, the timecard is incorrect. (The amount of the charge is not considered in this survey) • For sample size 80, 7 or less incorrect cards are acceptable. • For sample size 50, 4 or less incorrect cards are acceptable. • For sample size 32, 3 or less incorrect cards are acceptable. • Perform a second survey in a subsequent week. • Report the results of both surveys in the VTC brief

  5. Sample data collection form

  6. Lean RepairTimekeeping Event[Your Activity Name] Presenter: [Name] Lean Coordinator: [Name] 18 Jul 06

  7. Excess Material Update

  8. IPE Kaizen Measures

  9. Timekeeping Definitions • Unused Capacity = Assigned production man hours minus actual production man hours charged to jobs (see JFMM Vol II 4.6.3) • Missing time = Available Hours - Production Hours - Non-Production Hours (See NEMAIS report 700-2) • Overtime = Individual hours charged above 8 hours a day during the normal 5 day work week, plus holidays & weekends • Validity – A test at 95% confidence that charges reflect actual work (AQL of 4% defective)

  10. Unused Capacity (Hours)By Department (Oct 05 – Mar 06) --Sample-- Provide your data & delete this callout

  11. Missing Time (Hours)By Department (Oct 05 –Mar 06) --Sample-- Provide your data & delete this callout

  12. Top Five Overtime Users(Lost Time, Leave & Training Same Codes/Shops) Legend:(Identify Codes/Shops to 1 through 5. They will be the same in all four charts) --Samples-- Provide your data & delete this callout

  13. Production Charge ValiditySample size = XX(95% confidence; AQL 4%) Comments:

  14. Timekeeping Kaizen Pictures Add pictures that show the project Delete this callout

  15. Lessons Learned: Recommendations: Timekeeping Event

  16. FY06 Lean Program Overview Indicate % progress to items in 13 Sep 05 FMO letter. Then delete this callout box 7/18/06

  17. Preparation for Sept Case Study VTC • Topic of Case Study: • Purpose of the Case Study: • External Participants: • Publish/Share Where:

  18. RMC/FMA Input Needed • Lean contract support needed FY07 • FY07 guidance letter inputs

  19. Other Items to Report • [List any items of general interest] If the page number > 15, your brief is not Lean! Also, recheck file size < 5 Megs. Delete this callout.

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