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Sales, Production, Inventory Management

PQR analysis 10 9 8 7 6 5 4 3 2 1 0

Delivery performance

Forecasting

Product introduction

Production smoothing

Inventory turns

Kanban

Standard WIP Capacity planning

Supermarket Visual pull signals

anagement

Production smoothing

Lean Manufacturing Techniques

Value stream mapping Right-sized equipment 10 Takt time 9 8 Sustainment of gains One-piece flow 7 6 Handling reduction Pull system 5 4 3 2 Line balancing SMED (setup) 1 0 Value-added ratio TPM Machine reliability Jidoka (autonomation) Standard work OEE Flow velocity Productivity (labor cost) Facility layout

Total Quality Management


SPC Prevention vs. detection 10 9 8 7 6 5 4 3 2 1 0 Best practices

First-pass quality

Process control

Information flow

Poka-yoke

Supplier quality

Waste reduction

Problem-solving tools Quality assurance

5-S ISO 9000 structure

rocess control

Waste reduction

Total Organizational Buy-in

Effective leadership Team building Profitability Safety focus WIIFM (incentives) Change management

Vision 10 9 8 7 6 5 4 3 2 1 0

Action plan Policy deployment Enfranchisement Performance-based pay Skills training CI culture Kaizen promotion office Morale

Lean training Visuals/communication

rmance-based pay

1 Lean Manufacturing Techniques LMT Value stream mapping Takt time One-piece flow Pull system SMED (setup) OEE Flow velocity Productivity (labor cost) Facility layout Standard work Jidoka (autonomation) Machine reliability TPM Value-added ratio Line balancing Handling reduction Sustainment of gains Right-sized equipment

3 Sales, Production, Inventory Management SPIP PQR analysis Forecasting Production smoothing Kanban Supermarket Visual pull signals Capacity planning Standard WIP Inventory turns Product introduction Delivery performance

Goal 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

Actual

Total Organizational Buy-in TOB Vision Action plan Policy deployment Enfranchisement Performance-based pay Skills training CI culture Kaizen promotion office Morale Visuals/communication Lean training Change management WIIFM (incentives) Safety focus Profitability Team building Effective leadership

Goal 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10

Actual

Goal 10 10 10 10 10 10 10 10 10 10 10

Actual

Total Quality Management TQM SPC Best practices Process control Poka-yoke Waste reduction 5-S ISO 9000 structure Quality assurance Problem-solving tools Supplier quality Information flow First-pass quality Prevention vs. detection

Goal 10 10 10 10 10 10 10 10 10 10 10 10 10

Actual

Lean Manufacturing Techniques

Sales, Production, Inventory Management


PQR analysis 10 9 8 7 6 5 4 3 2 1 0

Value stream mapping Right-sized equipment 10 Takt time 9 Sustainment of gains 8 One-piece flow 7 6 Handling reduction Pull system 5 4 3 2 Line balancing SMED (setup) 1 0

Delivery performance

Forecasting

Product introduction

Production smoothing

Value-added ratio TPM Machine reliability

OEE Flow velocity Productivity (labor cost)

Inventory turns

Kanban

Standard WIP Capacity planning

Supermarket Visual pull signals

Jidoka (autonomation) Facility layout Standard work

Total Organizational Buy-in


Vision 10 9 8 7 6 5 4 3 2 1 0

Total Quality Management


SPC 10 9 8 7 6 5 4 3 2 1 0

Effective leadership Team building Profitability


Safety focus

Action plan Policy deployment Enfranchisement


Performance-based pay

Prevention vs. detection First-pass quality

Best practices Process control

Information flow

Poka-yoke

WIIFM (incentives) Change management Lean training Visuals/communication

Skills training
Supplier quality Waste reduction

CI culture Kaizen promotion office Morale Quality assurance ISO 9000 structure
Problem-solving tools 5-S