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First year project rev

First year project rev. AH BEE GOH 19 MARCH 2011 2 April 2011. TITLE.

paul-rich
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First year project rev

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  1. First year project rev AH BEE GOH 19 MARCH 2011 2 April 2011

  2. Presentation title TITLE The dependency and necessity on twin forces; ROFO model and KNOWLEDGE COMPETENCY to close the gap -execute Lean Sigma strategy

  3. F1 AND F2 FULFILLED F1-LACK OF KNOWLEDGE GAP GAP CLOSED F2-NO OWNERSHIP OF TOTAL PROCESS FIG. 4.0-2 Presentation title

  4. Presentation title APPLICATION OF F1 AND F2 FORCES TO EXECUTE LEAN SIGMA F1- KNOWLEDGE COMPENTENCY Lean sigma F2-ROFO MODEL FIG. 4.0-2

  5. Presentation title Bloom taxanomy & COP Knowledge competency Learning systems Managers Professionals Supervisors and technicians Production workers Level 6 Level 5 Level 4 Level 3 Level 2 Level 1 define Nonaka model Action learning Training procedure Sitting with Nellie F1 Hypothesis/ ANOVA measure 0ne piece flow Takt time Lean sigma Kanban pull control 7 waste removal 5S Value stream mapping Visual control SPC Bloom taxanomy & COP analysis improvement F2 R O F O

  6. Presentation title SURVEY QUESTIONS AND INTERVIEW • SURVEY QUESTIONS.doc • Interview on Willingness and ability.ppt

  7. Presentation title Knowledge competency Level 6 Level 5 Level 4 Level 3 Level 2 Level 1 Learning systems Knowledge workers Nonaka model Action learning Training procedure Sitting with Nellie F1 Managers Professionals Production workers technicians Knowledge competency Fig.7.2b

  8. Presentation title R R O R OWNERSHIP RESPONSIBILTY R F2 Ownership of total process O F ON- TIME CORRECTIVE ACTION FOCUS

  9. Presentation title define measure Hypothesis/ ANOVA 0ne piece flow Takt time Lean sigma Kanban pull control 5S 7 waste removal SPC Value stream mapping Visual control analysis improvement

  10. Presentation title DEFINITION OF ROFO • ROFO- is a model to develop self – internalisation and motivation to own total process with the objective to execute tasks/ strategies successfully and on-time. • It stands for; • R- responsibility. • O- ownership. • F- focus. • O- on-time corrective action. • In the ROFO model , there is a fine difference between responsibility and ownership.

  11. Presentation title DEFINITION OF KNOWLEDGE COMPETENCY • The ability of the knowledge worker to apply using a combination of skills / experience, knowhow to execute a task successfully. experience knowhow ability analytical On – the job skills Problem- solving managerial

  12. Presentation title DEFINITION OF LEAN • It is a systematic approach to identifying and eliminating waste through continuous improvement, flowing the product at the pull of the customer in pursuit of perfection. From; National Institute of Standards and technology Manufacturing Extension Partnership’s Lean Network ( Practioner’s guide to Statistics and Lean Six Sigma for process improvements).

  13. Presentation title DEFINITION OF 7 WASTES • Over- production- producing items earlier or in bigger quantities than needed by customers. The more you produce the more you will generate wastes such as more manpower is needed and more transportation and storage areas etc. • Waiting- Any waiting is considered a waste such as waiting for materials or watching to serve automated machine. • Transportation- moving work in process (WIP) from one location to another. • Over processing and incorrect processing- Taking unneeded steps to processthe parts- Inefficient processing due to poor tools or jigs.

  14. Presentation title DEFINITION OF 7 WASTES 5. Excess inventory- Excess raw materials, WIP and finished goods which give rise to obsolescence. 6. Unnecessary motion- Employees have to move in an unnecessary manner which will not add any value . 7.Defects and quality problems.- Producing defective parts which have to be scrapped or reworked.

  15. 7 Wastes In Manufacturing Over Production Unnecessary motion Over Processing Rejects and Defects Seven Wastes Inefficient Transportation Waiting Times Excess inventory Presentation title ELIMINATION OF 7 WASTES

  16. Presentation title DEFINITION OF SIX- SIGMA IN STATISTICAL MEANING With 4.5 sigma at the mean it achieves 3.4 defects per million with 25% design margin

  17. Presentation title DEFINITION OF SIX- SIGMA IN STATISTICAL MEANING With 6 sigma at the mean it achieves 2 defects per billion with 50% design margin

  18. Presentation title DEFINITION OF DMAIC • DMAIC stands for ; • Define the problem- understand the requirements of customer and what goals we want to achieve. • Measure the the existing process and collect relevant data. • Analyse the current performance to isolate the problem. Through analysis ( statistical and qualitatively) , formulate and test hypothesis about the root cause. • Improve the problem by selecting the solution based on the ‘ analysis “ stage. • Control the improved process to ensure the targets are met

  19. Presentation title Define Measure Control Analyse Improve yes no Measure sys effective ? no yes no yes Problem exists In lean cells? Process capable ? Sustainable ? Process capable ? yes no no yes No- close the project Remove variation completely Close the project Close the project

  20. Presentation title Thank you very much for your attention. Any questions?

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