Selecting the Right Manufacturing Improvement Tools

1. Introduction The SceneThe Response The Tools Lean Manufacturing Cost Cutting – Does It Work? Why Do Executives Persist in Cost Cutting? Summary 2. Aligning the Organization Why We Must Align the Organization Aligning for Manufacturing Excellence Developing and Using an Asset Management Strategy as an Alignment Tool CEO Compensation: MIS-Aligning the Organization Initiative Overload: a MIS-Alignment Issue Closing 3. Innovation Cost Cutting vs. Creating an Innovative Environment Getting Lower Costs through “Little Innovation” Creating Expectations Outsourcing/Offshoring – The Loss of Innovation Two Scenarios Human Capital – The Heart of Innovation and Value Creation Other Human Asset Valuation Methods Closing 4. Leadership and Teamwork Introduction to Leadership Models Leaders v. Managers Vision, Reality, Courage and Ethics Personal Humility and Professional Resolve Building Character through Principles Aligning the Organization Five Practices of Exemplary Leadership The 21 Irrefutable Laws of Leadership Inspiring Ordinary People to Extraordinary Performance Summary – Common Traits of Leadership Teams and Teamwork – A Model for Excellence The Dysfunctions of Teams Closing 5. Managing Change Introduction Articulate a Compelling Reason for Change Apply Leadership and Management Principles Communicate the Strategy and Goals Facilitate Employee Implementation of the Change Process Measure the Results: Reward Good Behaviour; Challenge Bad Behaviour Stabilize the Organization in the New Order Succession Planning and Management Beta’s Omega Division Better Succession Management Selecting the Right Managers Sustaining the Improvement Closing 6. Business Level FMEA The Manufacturing Plant as a Business System Business Level Failure Modes and Effects Analysis (FMEA) Typical Results Selecting the Right Tools Beta’s Allen Central Plant Beta’s Swampton Plant Beta’s Martin Plant Beta’s Leets Plant Beta’s Van Lear Plant Beta’s Blany Plant Beta’s Ivel Plant Summary 7. Lean Manufacturing Lean Manufacturing – A Very Brief History Lean Characteristics The Toyota Way Philosophy – Long Term Thinking Processes – Eliminate Waste People and Partners – Respect, Challenge, and Grow Them Problem Solving – Continuous Improvement and Learning Keep Things Simple Toyota Production System – Summary Decoding the DNA of the Toyota Production System Beta’s Banner Division Banner Division’s Boldman Plant Banner Division’s Blue River Plant Summary 8. Kaizen Introduction Ideas Are Free Major Principles of Kaizen Kaizen and Management 5S Standardization Elimination of Muda (Waste) Kanban Beta’s Dorton Plant Closing 9. Total Productive Maintenance (TPM) Fundamentals of TPM Overall Equipment Effectiveness (OEE) OEE/TPM and Safety Performance Operator Care Operator/Owner Guidelines Maintainer/Improver Guidelines Quick Changeover Beta’s Ivyton Plant Beta’s Grethel Plant Closing 10. Six Sigma Definition of Six Sigma The Methodology An Alternative Application of Six Sigma Principles Beta’s Waldo Plant Beta’s Staffordville Plant Beta’s Teaberry Plant Six Sigma and Lean Manufacturing Summary 11. Supply Chain Management Supply Chain Management – One Model Supply Chain Management – Another Model Differentiating and Managing Customers Cost of Service Good Suppliers Policy Deployment Functional Organizations vs. Supply Chain Organizations Beta’s Falcon Plant Beta’s Tomahawk Division Beta’s Topmost DPD Division Summary 12. Reliability Centered Maintenance (RCM) Introduction RCM Standard SAE JA1011 An Example Criticality Analysis RCM and Developing a Maintenance Strategy Potential RCM Pitfalls and Suggestions PM Optimization – RCM in Reverse Beta’s Lowhansville Plant Beta’s Carr Creek Plant Beta’s Oil Springs Plant RCM and TPM – The Relationship RCM and Six Sigma – Common and Uncommon Characteristics Summary 13. Predictive Maintenance/Condition Monitoring Introduction Cost Reduction Benefit of Condition Monitoring PM and Increased Costs Common Mistakes in Condition Monitoring Programs Condition Monitoring – Understanding and Managing the Degradation Process Predictive Maintenance/Condition Monitoring Technologies Vibration Analysis The Basics of Vibration Analysis Lubrication/Fluid Analysis Infrared Thermography Motor and Electrical Testing Airborne Ultrasound Testing Operator Condition Monitoring Contracting Predictive Maintenance Beta’s Boons Camp Plant Beta’s Stanville Plant Beta’s Dwale Plant Beta’s Watergap Plant Summary 14. Root Cause Analysis Introduction Three Common Approaches Five Whys Cause & Effect Diagram with the Addition of Cards- CEDAC Apollo Root Cause Analysis Methodology RCA Example RCA Rt The Development of a Cohesive Approach The Importance of Problem Definition and Follow Through Cause Trees Action Management Incidents and Ongoing Concerns Summary 15. Closing Beta’s Strategy Nominal Hierarchy for Application of the Strategy and Tools Appendices A – Planning and Scheduling B – Performance Measurement C – Other Tools and Strategies