
A learning objective of the course. The outline summarizes the key lessons in the course.
How do we link the vision, mission, values of a company into something easy to understand and live by. Why is it important to know before starting any initiative.
A plant manager is asked by the CEO of a company to ramp up production to meet the customers' orders and return the company to profitability to the same level as before COVID pandemic. Many of his direct reports have left the company and he has a skeleton crew left. There are four cases in which the plant manager could find himself in. Which case do you think the plant manager would have preferred to see ?
Any successful initiative in a company must be supported by the employees. This lecture shows the factors affecting the willingness to be involved
New United Motor Mfg (NUMMI) was a model plant for lean production system. Here the students will see the model of this system and examples of visual controls. The instructor worked here for 15 years as an Engineering Manager
Develop visual management of SQDCM by selecting one KPI for safety, quality, delivery, costs, and morale, using templates and a museum board to track data and drive root cause improvements.
Learn to construct a regional delivery board with color coded calendar chart and monthly trend lines, using first time capability metrics, a check sheet, and an issue tracking sheet.
Visualize cost performance with a color-coded board, using a check sheet and cost KPI to track no part scrap via green, yellow, and red statuses and monthly trend lines.
Practical guides to update templates with different dates and criteria. These templates can be used for any dates and for any criteria
Craft a clear problem description and definition within a visual, one-page report that links standard versus actual conditions, emphasizes data over opinion, and guides focused root-cause investigation.
Identify the point of cause by tracing the issue upstream from where it first appears on the assembly line, guiding containment decisions and the subsequent investigation.
Learn to identify root causes with fishbone diagrams and the five whys, distinguishing direct causes from root effects and guiding countermeasures and containment in problem solving.
Address root causes with long term countermeasures, including process and product design changes and error proofing, evaluated by time, costs, and effectiveness to prevent recurrence.
Implement follow up and lessons learned in practical problem solving by verifying progress, adapting countermeasures as needed, and updating standards to apply lessons learned to similar processes.
The instructor is president of a newly established company called Refote LLC which stands for Reaching for Excellence.
This course is for any organization wanting to start a Continuous Improvement program using visual management techniques. Visual management is a key strategy in lean production system, especially visual controls where problems are visible at a quick glance. This course teaches a simple but effective visual management method to improve Safety, Quality, Delivery, Cost and Morale. It is a practical guide for CEOs, Heads of Operations as well as for Team Leaders or Supervisors to run daily management operations as well as to deploy new goals and objectives throughout the company. The students will learn about general management principles, vision, mission, values and deployment method of goals; how to set up the visual management system; communicate the information and maintaining the system. The Key Performance Indicator of Safety, Quality, Delivery, Cost, Morale is used as a set of metrics to read across the comprehensive performance of the work unit. A simple color scheme of Red, Yellow, Green is used to denote the current conditions to targets. The team leaders or supervisors are provided with guidelines to react to unfavorable conditions with problem solving methods. Insights from the instructor from the perspectives of a CEO and of a worker are provided to help successful implementation.