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1/22 234265807.

xls
Plant: oo
Manufacturing Lean Assessment
Cell: oo
Date: oo
Assessor: oo
Overall Score
People N/A
N/A
Total 7.1 Continuous improvement Culture N/A
Ma! 7.2 Organi"ation N/A
7.# Performance Management N/A N/A 1$
%ust&'n&Time N/A %i(o)a *+uilt in ,ualit-. N/A
/.1 Pull s-stem 0it1in t1e factor-N/A $.1 An(on N/A
/.2 Pull s-stem from suppliers N/A $.2 Po)a 2o)e N/A
/.# Level pro(uction N/A $.# 3ull 4or) S-stem N/A
/.5 One piece flo0 N/A
Total Pro(uctive Maintenance N/A 6uic) C1angeover N/A Stan(ar(i"e( 4or) N/A /S 4or)place Organi"ation N/A
5.1 Autonomous Maintenance N/A #.1 6uic) C1angeover N/A 2.1 Stan(ar(i"e( 4or) N/A 1.1 /S 4or)place Organi"ation N/A
5.2 Planne( Maintenance N/A 2.2 Ta)t Time N/A 1.2 7isual 3actor- N/A
5.# Overall 8,uipment 8ffectiveness N/A 1.# 7isual Control N/A
5.5 TPM Training N/A
Lean Temple
Best Quality Lowest Cost Shortest Lead Time
Through shortening the production flow by eliminating waste
Full Work System
Poka Yoke
Andon
5S
Workplace
Organiation
Standardied
Work
Total
Producti!e
"aintenance
#uick
$hangeo!er
One Piece Flow
Pull Systems
%e!el Production
Kaizen
Fle&ible' $apable'
(ighly "oti!ated
People
Operational Stability
Just-In-Time Jidoa
2/22 234265807.xls
Plant/ Cell9 oo
/S 4or)place Organi"ation Section9 1
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
1.1.1 < = N/A 5S, if performed orretl!, "ill #a$e t#e follo"in% res&lt:
X
>
1.1.2 < = N/A > A lean "or'in% area "#ere people are #app! to "or'.
X
Score 9 1.1 /S 4or)place Organi"ation
1.1.# < = N/A
X (.(.( )ele$ant tools, parts, in speified loations
(.(.2 5S *&arantine area f&ntionin%
1.1.5 +s t#ere a leanin% s#ed&le operated in t#e area < = N/A
X (.(.3 ,al'"a!s leared of o-str&tions
(.(.4 Cleanin% s#ed&le a$aila-le
1.1./ < = N/A
X (.(.5 Cleanin% standards $isi-le and desripti$e
(.(.6 A&dits and ation plans e$ident
1.1.$ < = N/A
X (.(.7 All emplo!ees #ad a"areness trainin%
1.1.7 < = N/A
X
Total
Ma!
? N/A
5s and .is&al /ator! are t#e 'e!stone of 0ean 1an&fat&rin%. 2#e onept is simple -&t an pro$e diffi&lt to implement and maintain. 3o"e$er, &nless 5s and .is&al /ator! are in plae t#e
f&ndamental -&ildin% -lo's of lean 42P1 and Standardised ,or'5 annot -e maintained. 5s "ill &ltimatel! pro$ide a platform for t#e &lt&re of 'ai6en.
1.1 /S 4or)place
Organi"ation
Are onl! t#e rele$ant tools, e*&ipment, parts and do&mentation a$aila-le in
t#e area.
Sort,
Set,
S#ine,
Standardise,
S&stain
An en$ironment t#at "ill s&stain small inremental
impro$ements.
Are t#ere 5S *&arantine areas a$aila-le and f&ntionin% in line "it# t#e
a%reed proess.
All toolin%, e*&ipment, %a&%es, do&mentation and parts 'ept in speified
addressed loations. All footprints respeted.
Are Cleanin% standards "#i# are $is&al and desripti$e, displa!ed in t#e
"or' area
Do s&per$isors and mana%ers &nderta'e re%&lar 5s a&dits, "it# ation plans
e$ident for non7onformin% items
3a$e all emplo!ees #ad a"areness trainin% and &nderstand t#e p&rpose of 5s

) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
#/22 234265807.xls
Plant/ Cell9 oo
/S 4or)place Organi"ation Section9 1
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
5s and .is&al /ator! are t#e 'e!stone of 0ean 1an&fat&rin%. 2#e onept is simple -&t an pro$e diffi&lt to implement and maintain. 3o"e$er, &nless 5s and .is&al /ator! are in plae t#e
f&ndamental -&ildin% -lo's of lean 42P1 and Standardised ,or'5 annot -e maintained. 5s "ill &ltimatel! pro$ide a platform for t#e &lt&re of 'ai6en.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
1.2 7isual 3actor-
1.2.1 < = N/A .is&al /ator!, if &sed orretl! "ill #a$e t#e follo"in% res&lt:
X
>
1.2.2 < = N/A
X Score 9 1.2 7isual 3actor-
(.2.( 2eam -oards "it# <P+
(.2.2 .is&al one point lessons
1.2.# Are a&dit s#eets learl! displa!ed and &p to date < = N/A (.2.3 A&dit s#eets &p to date
X (.2.4 Central information area "it# <P+
Total
1.2.5 < = N/A Ma!
X ? N/A
1.# 7isual Control
1.#.1 < = N/A .is&al Control, if &sed orretl! "ill #a$e t#e follo"in% res&lt:
X
>
1.#.2 Are de$iations to esta-lis#ed standards *&i'l! and $is&all! identified < = N/A
X Score 9 1.# 7isual Control
(.3.( .is&al mar'in%s
(.3.2 De$iations to esta-lis#ed standards
1.#.# < = N/A (.3.3 .is&al ontrol 4<amis#i-ai5 s!stem
X
Total
Ma!
? N/A
Total
Ma!
? N/A
Are t#ere team -oards in t#e team prod&tion area s#o"in% a%reed metris
e.% safet!, *&alit!, prod&tion,ost
All t#e ans"ers to an!
*&estions an -e fo&nd in t#e
rele$ant area "it#in 3
min&tes.
All t#e ans"ers to an! *&estions an -e fo&nd in t#e
rele$ant area "it#in 3 min&tes
Are $is&al one point 0essons displa!ed in t#e prod&tion areas s#o"in%
*&alit! and safet! onerns
+s t#ere a entral information area s#o"in% &p to date <P+s t#at an -e
&sed to dri$e ontin&o&s impro$ement and mana%e prod&tion operations.
Are $is&al mar'in%s e$ident, s&# as 'an-an s*&ares, to maintain
prod&ti$it! and impro$e *&alit!
2#e ad#erene to $is&al
standards t#at s&pport t#e
onept of mana%ement -!
exeption
2#e teams "ill -e mana%in% t#eir prod&tion &sin%
mana%ement -! exeption. A-normalities lear to all.
Are all non standard fre*&ent tas's tra'ed and a&dited &sin% a $is&al
ontrol -oard
/S 4or)place
organi"ation section
5/22 234265807.xls
Plant/ Cell9 oo
Stan(ar(i"e( 4or) Section9 2
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
2.1 Stan(ar(i"e( 4or)
2.1.1 All proesses re*&irin% operator inter$ention are standardised. < = N/A
X
>
2.1.2 < = N/A
X
2.1.# < = N/A Score 9 2.1 Stan(ar(i"e( 4or)
X
2.(.( All prod&tion = non prod&tion proesses
2.1.5 < = N/A 2.(.2 ,or' element s#eets
X
2.(.3 Created -! t#e team mem-ers
2.1./ < = N/A 2.(.4 .al&e Added 9 8on .al&e Added
X
2.(.5 ,or' -alane -oard
2.1.$ < = N/A 2.(.6 )e%&lar a&dits
X
2.(.7 2rain "it# standard "or'
2.1.7 < = N/A
X
Total
Ma!
? N/A
Standardi6ed ,or' is a met#od for teams to do&ment t#eir proesses %i$in% t#em more ontrol in t#e da!7to7da! r&nnin% of t#eir operations. +t inorporates all t#e safet! and *&alit! aspets
re*&ired to s&pport emplo!ees and &stomers "#ilst identif!in% "aste "#i# an -e eliminated to red&e ost and impro$e prod&ti$it!. Standardised ,or' is seen as a fo&ndation tool for 'ai6en
impro$ements entered aro&nd t#e ati$ities of people.
Corret appliation of Standardi6ed ,or' "ill #a$e t#e
follo"in% res&lt:
A "ritten do&ment
identif!in% ea# step in t#e
"or' proess allo"in%
ad#erene to t#e a%reed
standard and a -aseline for
impro$ement.
A ro-&st 'no"led%e mana%ement s!stem retained and
o"ned -! prod&tion "#i# ass&res t#e ontin&o&s
ad#erene to *&alit! and prod&ti$it! standards.
+s t#e Standardi6ed ,or' s&pported -! "or' element s#eets to pro$ide
detail for safet!,*&alit! and te#ni*&e "#ere re*&ired
All Standardised ,or' do&mentation is reated -! t#e team mem-ers "it#
t#e %&idane and s&pport of t#e team leader. >a# element of "or', diret
and indiret, #as an a%reed time esta-lis#ed -! t#e team.
.al&e Added 9 8on .al&e Added steps are identified in t#e Standardised
,or' do&mentation and "#ere$er possi-le is displa!ed $is&all! .
A&dit riteria for 2eam 0eader, S&per$isor, and 1ana%ement esta-lis#ed
-ased &pon fre*&en! of #e', ompeten!.
2rainin% of all ne"omers is performed -! t#e 2eam 0eader &sin% t#e
appropriate Standardised ,or' C#art and ,or' Step S#eets &ntil re*&ired
le$el of ompetene in prod&ti$it! and *&alit! is a#ie$ed.
+nitial Standardised ,or' is reated as part of t#e Prod&tion De$elopment
proess. All prod&tion trials -ased &pon Standardised ,or' de$eloped -!
experiened prod&tion operators.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
//22 234265807.xls
Plant/ Cell9 oo
Stan(ar(i"e( 4or) Section9 2
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
Standardi6ed ,or' is a met#od for teams to do&ment t#eir proesses %i$in% t#em more ontrol in t#e da!7to7da! r&nnin% of t#eir operations. +t inorporates all t#e safet! and *&alit! aspets
re*&ired to s&pport emplo!ees and &stomers "#ilst identif!in% "aste "#i# an -e eliminated to red&e ost and impro$e prod&ti$it!. Standardised ,or' is seen as a fo&ndation tool for 'ai6en
impro$ements entered aro&nd t#e ati$ities of people.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
2.2 Ta)t Time
2.2.1 < = N/A 2a't 2ime, if performed orretl!, "ill #a$e t#e follo"in% res&lt:
X
>
2.2.2 < = N/A
X Score 9 2.2 Ta)t Time
2.2.( +dentified on Standardised ,or' C#arts
2.2.# < = N/A
X 2a't 2ime is re$ie"ed periodiall!
Std ,or' and -alane #arts are re$ie"ed
2.2.5 < = N/A
X 1in71ax le$els re$ie"ed "it# ta't
Prod&tion performane monitored
2.2./ +s t#e prod&tion performane monitored -! mana%ement < = N/A
X Prod&tion performane data &sed
Total
2.2.$ < = N/A Ma!
X ? N/A
Total
Ma!
? N/A
+s t#e tar%et !le time and proess !le time identified on Standard "or'
om-ination ta-le
> Proesses are flexed in line "it# &stomer demand "it#
spare apait! onsolidated for ontin&o&s impro$ement
ati$ities.
;&ildin% to &stomer demand
deri$ed -! di$idin% 4,or'
2ime x ?peratin% )ate5 -!
C&stomer Demand.
+s t#e ta't time re$ie"ed periodiall! 4-! mont#, or prod&tion period5 -!
prod&tion ontrol and omm&niated to all prod&tion and non prod&tion
areas
,#en t#e ta't time #an%es, is t#e standardi6ed "or' re$ie"ed and "or'
re-alaned
2.2.
2
2.2.
3
Are t#e min7max le$els and standard in proess sto's re$ie"ed and
ad@&sted in line "it# ta't #an%es
2.2.
4
2.2.
5
2.2.
6
+s prod&tion performane data &sed -! mana%ement to ens&re t#at
onerns are -ein% identified and resol$ed
Stan(ar(i"e( 0or)
section
$/22 234265807.xls
Plant/ Cell9 oo
6uic) C1angeover Section9 #
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
#.1 6uic) C1angeover
#.1.1 < = N/A AC?, if performed orretl! "ill #a$e t#e follo"in% res&lt:
X
>
#.1.2 < = N/A Score 9 #.1 6uic) C1angeover
X
3.(.( C#an%e7o$er times are -ein% tra'ed
#.1.# < = N/A 3.(.2 S#in%oBs 5 step met#odolo%! = "all#art
X
3.(.3 1&lti7disiplined teams
#.1.5 +s (st off inspetion apa-ilit! a ore ompetene "it#in t#e team < = N/A 3.(.4 (st off inspetion apa-ilit!
X
3.(.5 All %a&%es and tools are stored ad@aent
#.1./ < = N/A 3.(.6 Standard ,or' S#eets
X
3.(.7 1ana%ement sponsor ideas and deplo!ment
#.1.$ < = N/A 3.(.8 1ana%ement re$ie" #an%e7o$er
X
Total
Ma!
#.1.7 Are AC? impro$ements deplo!ed aross t#e failit!. < = N/A ? N/A
X
#.1.@ < = N/A Total
X Ma!
? N/A
A&i' #an%eo$er an -e seen as t#e paema'er of lean implementation. +n a man&fat&rin% en$ironment, t#e #an%e7o$er times on e*&ipment "ill determine t#e sto' le$els #eld in t#e fator!. 2#e
more t#e #an%e7o$er time is red&ed t#e more sto' an -e eliminated from t#e s!stem. 2#is #as t#e added ad$anta%e of red&in% lead time and inreasin% flexi-ilit! in meetin% &stomer demand.
Are #an%eo$er times -ein% tra'ed prod&t to prod&t -! ea# operatin%
team or ell of e*&ipment
A pro%ressi$e red&tion in in$entor! le$els in relation to
t#e #an%e7o$er time.
Performin% a #an%e o$er
from %ood prod&t to %ood
prod&t in t#e least time
possi-le.
+s S#in%oBs 5 step met#odolo%! and "all#art &sed to s!stematiall! red&e
#an%e7o$er times. 2#is ati$it! is r&n -! t#e team "it# t#e s&pport of t#e
team leader
Are m&lti7disiplined teams in$ol$ed to 'ai6en t#e #an%e7o$er time, "it#
maintenane pla!in% an ati$e role in trials and modifiations
Are all %a&%es and tools stored ad@aent to t#e e*&ipment in line "it# 5s
met#odolo%!.
+s t#e #an%eo$er proess do&mented &sin% standard "or' s#eets and
$is&al Displa!s.
6uic) c1angeover
section
Does mana%ement re$ie" #an%e7o$er impro$ements and &se t#e opport&nit!
to eit#er red&e lot si6e or inrease -ottlene' apait!
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
7/22 234265807.xls
Plant/ Cell9 oo
Total Pro(uctive Maintenance Section9 5
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
4.(.( ) : 89A
X
C
4.(.2 ) : 89A
X
4.(.3 ) : 89A Sore : 4.( A&tonomo&s 1aintenane
X
4.(.( 5 Steps of A&tonomo&s 1aintenane 0
4.(.4 ) : 89A 4.(.2 2a% 1ana%ement S!stem 0
X
4.(.3 .is&al ontrol 4<amis#i-ai5 s!stem 0
4.(.5 +s a s'ills matrix a$aila-le to tra' A&tonomo&s 1aintenane ompeteneD ) : 89A 4.(.4 <e! maintenane lin'ed to andon 0
X
4.(.5 S'ills 1atrix 0
4.(.6 ) : 89A 4.(.6 A&alit! parameters &nderstood 0
X
4.(.7 ?>> o"ned -! teams 0
4.(.7 +s ?>> al&lated, anal!sed, and ated &pon -! t#e team mem-ers. ) : 89A
X
2otal 0
1ax 0
E 89A
2P1 is a $ital in%redient of t#e fo&ndation of 0ean 1an&fat&rin%. +t pro$ides t#e neessar! le$el of e*&ipment performane 485E ?>>5 to ta'e ad$anta%e of t#e more ad$aned tools and te#ni*&es fo&nd in t#e
lean tool-ox. A sta-le le$el of performane is $ital to t#e s&essf&l operation of t#e "#ole 0ean Prod&tion S!stem. A $ar!in% le$el of e*&ipment performane "ill @eopardise attempts to -&ild to &stomer demand
and minimise t#e in$entor! #eld "it#in t#e fator! "alls. Poor 2P1 means #i%# le$els of &nneessar! safet! sto' and e*&ipment t#at deteriorates -efore its time. A&tonomo&s 1aintenane is t#e ornerstone of
an! 2P1 initiati$e. S&ess or fail&re of 2P1 "ill -e deided -! a fator!Bs ommitment to A&tonomo&s 1aintenane.
4.( A&tonomo&s
1aintenane
+s t#e s!stemati appliation of A&tonomo&s 1aintenane appliedD A&tonomo&s 1aintenane, if performed orretl!, "ill #a$e t#e
follo"in% res&lt:
2eams performin% fre*&ent
maintenane ati$ities to
minimise e*&ipment
-rea'do"ns.
Self moti$ated, a&tonomo&s teams performin% 'ai6en
ati$ities on a dail! -asis to impro$e t#e ondition of
t#eir e*&ipment, and t#e ?>> performane of t#e
ell9man&fat&rin% 6one.
+s t#ere a 2a% 1ana%ement S!stem in plae to identif! a-normalities diso$ered on
e*&ipment in t#e team area. A-normalities are tra'ed and ated &pon -! t#e team and
maintenane
+s a .is&al ontrol 4<amis#i-ai5 s!stem in plae to tra' dail!, "ee'l!, mont#l!
maintenane ati$ities for t#e team.
Are 'e! maintenane ati$ities 4inl&din% life expetan! of "or'in% parts5 $is&all!
monitored and, if possi-le, lin'ed to t#e andon s!stem to pre$ent defets and
-rea'do"ns.
Are *&alit! parameters f&ll! &nderstood -! t#e team and #o" t#ese are affeted -!
ma#ine performane and apa-ilit!
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
@/22 234265807.xls
Plant/ Cell9 oo
Total Pro(uctive Maintenance Section9 5
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
2P1 is a $ital in%redient of t#e fo&ndation of 0ean 1an&fat&rin%. +t pro$ides t#e neessar! le$el of e*&ipment performane 485E ?>>5 to ta'e ad$anta%e of t#e more ad$aned tools and te#ni*&es fo&nd in t#e
lean tool-ox. A sta-le le$el of performane is $ital to t#e s&essf&l operation of t#e "#ole 0ean Prod&tion S!stem. A $ar!in% le$el of e*&ipment performane "ill @eopardise attempts to -&ild to &stomer demand
and minimise t#e in$entor! #eld "it#in t#e fator! "alls. Poor 2P1 means #i%# le$els of &nneessar! safet! sto' and e*&ipment t#at deteriorates -efore its time. A&tonomo&s 1aintenane is t#e ornerstone of
an! 2P1 initiati$e. S&ess or fail&re of 2P1 "ill -e deided -! a fator!Bs ommitment to A&tonomo&s 1aintenane.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
4.2 Planned 1aintenane
4.2.( ) : 89A
X
C
4.2.2 Are t#e s#ed&led Planned 1aintenane ati$ities &p to date. ) : 89A C A trend to"ards fe"er -rea'do"ns
X
4.2.3 Are 1ean 2ime -et"een /ail&res and 1ean 2ime 2o )epair monitored. ) : 89A Sore : 4.2 Planned 1aintenane
X
4.2.( Central 1aster S#ed&le 0
4.2.4 Do P1 ati$ities inl&de operatin% teams to promote &nderstandin% of e*&ipment ) : 89A 4.2.2 1ean 2ime -et"een /ail&res 0
X
4.2.3 1ean 2ime to )epair 0
4.2.5 ) : 89A 4.2.4 P1 Ati$ities inl&de operatin% teams 0
X
4.2.5 Pre$entati$e 1aintenane 0
4.2.6 ) : 89A 4.2.6 P1 team assist in pro-lem sol$in% 0
X
4.2.7 /re*&ent and lon% do"ntime -rea'do"ns 'no"n 0
4.2.7 Croni -rea'do"ns 'no"n, monitored and resol$ed -! t#e P1 team ) : 89A
X
2otal 0
1ax 0
E 89A
Planned 1aintenane, in man! fatories, is a pro%ramme r&n -! an elite re" "#o retain t#e 'no"led%e and te#nial 'no"7#o" to fix #roni -rea'do"ns. 2#eir position of importane is maintained -! not s#arin% or
trainin% operatin% teams in #o" to fix or a$oid -rea'do"ns from o&rrin%. 2#e meas&re of a %ood Planned 1aintenane pro%ramme is #o" inte%rated and s&pporti$e of t#e operatin% teams t#e! are. 2#eir %oal
s#o&ld -e to disseminate as man! of t#eir ati$ities as possi-le to t#e operatin% teams "it# t#e $ie" to ma'in% t#em as self s&ffiient as possi-le.
+s a Central 1aster S#ed&le for all maintenane ati$ities #eld, monitored and &pdated
-! t#e maintenane team
Planned 1aintenane, if performed orretl! "ill #a$e t#e
follo"in% res&lt:
A ompre#ensi$e plan for t#e
s#ed&led maintenane of all
e*&ipment to eliminate
-rea'do"ns and poor
performane.
A Planned 1aintenane team t#at is moti$ated to"ards
#elpin% t#e operatin% teams maintain "orld lass
standards of ?$erall >*&ipment >ffeti$eness.
+s planned maintenane s#ed&led for all e*&ipment in t#e area in line "it# prod&tion
needs
Does t#e P1 team assist t#e operatin% teams "it# pro-lem resol&tion and ontin&o&s
impro$ement ati$ities to impro$e ?>>
A/22 234265807.xls
Plant/ Cell9 oo
Total Pro(uctive Maintenance Section9 5
Assessment No9 oo
:ate9 oo
Assessor9 oo
Su+;ect 6uestion <esult
2P1 is a $ital in%redient of t#e fo&ndation of 0ean 1an&fat&rin%. +t pro$ides t#e neessar! le$el of e*&ipment performane 485E ?>>5 to ta'e ad$anta%e of t#e more ad$aned tools and te#ni*&es fo&nd in t#e
lean tool-ox. A sta-le le$el of performane is $ital to t#e s&essf&l operation of t#e "#ole 0ean Prod&tion S!stem. A $ar!in% le$el of e*&ipment performane "ill @eopardise attempts to -&ild to &stomer demand
and minimise t#e in$entor! #eld "it#in t#e fator! "alls. Poor 2P1 means #i%# le$els of &nneessar! safet! sto' and e*&ipment t#at deteriorates -efore its time. A&tonomo&s 1aintenane is t#e ornerstone of
an! 2P1 initiati$e. S&ess or fail&re of 2P1 "ill -e deided -! a fator!Bs ommitment to A&tonomo&s 1aintenane.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
?$erall >*&ipment >ffeti$eness 4?>>5 is a po"erf&l al&lation t#at, if &sed appropriatel!, "ill pro$ide positi$e res&lts in performane "#en lin'ed "it# ot#er lean metris.
4.3.( ) : 89A ?>>, if &sed orretl! "ill #a$e t#e follo"in% res&lt:
X C
C >ffeti$e pro-lem sol$in% teams.
4.3.2 +s ?>> &sed -! t#e teams to meas&re t#e performane of t#eir onstraint ma#ine. ) : 89A
X Sore : 4.3 ?$erall >*&ipment >ffeti$eness
4.3.( ?>> al&lated 0
4.3.2 Constraint ma#ine 0
4.3.3 ) : 89A 4.3.3 Performane speed of e*&ipment 0
X 4.3.4 ,ee'l! meetin%s are #eld -! t#e teams 0
2otal 0
4.3.4 Are "ee'l! meetin%s #eld -! t#e teams to impro$e ?>> ) : 89A 1ax 0
X E 89A
4.4 2P1 2rainin%
4.4.( ) : 89A
X
4.4.2 Does t#e trainin% pro%ram inl&de pratial pro-lem sol$in% in a team -ased en$ironment ) : 89A
X Sore : 4.4 2P1 2rainin%
4.4.( >*&ipment trainin% 0
4.4.2 2eam -ased pro-lem sol$in% 0
4.4.3 +s 2P1 a"areness trainin% pro$ided for all emplo!ees ) : 89A 4.4.3 2P1 a"areness trainin% 0
X
2otal 0
1ax 0
E 89A
Total
Ma!
? N/A
4.3 ?$erall >*&ipment
>ffeti$eness
+s t#e ?>> al&lation -ein% &sed to meas&re A$aila-ilit!, Performane >ffiien! and
A&alit! )ate.
/o&sed teams "it# an in7dept# 'no"led%e of ma#ine
maintenane to o&nterat t#e Six ;i% 0osses.
2#e al&lation of ?>> is
&sed to #elp dri$e e*&ipment
and team performane to
ens&re t#e a#ie$ement of
prod&tion %oals and pro$ide
a sta-le platform for t#e
appliation of lean tools.
+s t#e performane speed of e*&ipment determined -! t#e s&pplier man&als, or if #a$in%
sine -een impro$ed "it# no affet on *&alit!, t#e ne" performane speed is s#o"n as
t#e norm
Are trainin% re*&irements for 2P1 -ased &pon t#e t!pe of e*&ipment &sed, fail&re
modes and t#e existin% teamsB s'ills matries 4inl&din% P1 team5
>ffeti$e 2rainin% "ill pro$ide t#e teams "it# t#e a-ilit! to -e
tr&l! a&tonomo&s in t#eir efforts to impro$e ?>> and implement
a ro-&st Prod&ti$e 1aintenane pro%ramme.
Pro$idin% t#e teams "it#
s&ffiient 'no"led%e and
apa-ilit! to r&n t#eir o"n
e*&ipment 9 line as
a&tonomo&sl! as possi-le.
Total pro(uctive
maintenance section
1/22 234265807.xls
Plant/ Cell9 oo
%ust&'n&Time Section9 /
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
/.1.1 Are min7max le$els learl! identified for in7proess material at point of &se < = N/A
X
>
/.1.2 < = N/A
X Score 9 /.1 Pull s-stem 0it1in t1e factor-
5.(.( Point of &se min7max le$els
/.1.# < = N/A
X 5.(.2 Card and all s!stems
5.(.3 Desi%nated footprint si6es
/.1.5 < = N/A
X 5.(.4 +n proess prod&tion9 prod&tion se*&ene
5.(.5 >xeption proesses
/.1./ < = N/A
X 5.(.6 0oation #an%e proess
5.(.7 Deli$er! fre*&en! and pa' &tilisation
/.1.$ +s t#e point of &se loation #an%e proess mana%ed -! t#e line or ell < = N/A
X 5.(.8 Co$ered -! standardi6ed "or'
/.1.7 3o" is t#e deli$er! fre*&en! and pa' &tilisation ati$el! promoted < = N/A
X
/.1.@ Are all material flo" proesses o$ered -! standardi6ed "or'. < = N/A
X
Total
Ma!
? N/A
?ne a le$el of sta-ilit! #as -een a#ie$ed in t#e prod&tion proesses t#e or%anisation an -e%in red&in% in$entor! of in proess and ra" materials. 2#e aim is to #a$e t#e Fri%#t *&antit!G of t#e
Fri%#t partG in t#e Fri%#t plaeG at t#e Fri%#t timeG.
/.1 Pull s-stem 0it1in
t1e factor-
1aterial /lo" "it#in t#e fator!, if performed orretl! "ill
#a$e t#e follo"in% res&lt:
/o&ses on t#e material flo"
from t#e point of reeipt to
t#e point of dispat#.
> A ro-&st material replenis#ment s!stem mana%ed -!
exeption and operated "it# t#e minim&m of in$entor!
Are ard and all s!stems 4ra' and floor parts5 in plae to o$er material
re*&irements
Are t#e desi%nated footprint si6es -ased on re7order point and transit
replaement time
+s proess prod&tion si%nal reei$ed from follo"in% proess or prod&tion
se*&ene -ased on &stomer demand
Are exeption proesses in plae to o$er de$iations from min7max at point
of &se
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
11/22 234265807.xls
Plant/ Cell9 oo
%ust&'n&Time Section9 /
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
?ne a le$el of sta-ilit! #as -een a#ie$ed in t#e prod&tion proesses t#e or%anisation an -e%in red&in% in$entor! of in proess and ra" materials. 2#e aim is to #a$e t#e Fri%#t *&antit!G of t#e
Fri%#t partG in t#e Fri%#t plaeG at t#e Fri%#t timeG.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
12/22 234265807.xls
Plant/ Cell9 oo
%ust&'n&Time Section9 /
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
?ne a le$el of sta-ilit! #as -een a#ie$ed in t#e prod&tion proesses t#e or%anisation an -e%in red&in% in$entor! of in proess and ra" materials. 2#e aim is to #a$e t#e Fri%#t *&antit!G of t#e
Fri%#t partG in t#e Fri%#t plaeG at t#e Fri%#t timeG.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
/.2.1 +s material olletion time slotted and in plae t#ro&%#o&t s&pplier -ase < = N/A
X
>
/.2.2 Are reei$in% proesses time slotted and in plae < = N/A
X Score 9 /.2 Pull s-stem from suppliers
5.2.( 2ime slotted material olletion
/.2.# < = N/A
X 2ime slotted reei$in% proesses
1ar'etplae si6ed "it# exeptions
/.2.5 < = N/A
X Standardi6ed "or'
Total
Ma!
? N/A
/.# Level pro(uction
/.#.1 < = N/A
X
>
/.#.2 +s prod&tion s#ed&led and monitored in line "it# &stomer demand < = N/A
X Score 9 /.# Level pro(uction
5.3.( Capait!9small lot si6es
/.#.# +s t#ere a pa'a%in% poli! for internal and external material s&ppl! < = N/A
X Prod&tion s#ed&led -! &stomer demand
Pa'a%in% poli!
Total
Ma!
? N/A
/.2 Pull s-stem from
suppliers
1aterial /lo" into t#e fator!, if &sed orretl! "ill #a$e t#e
follo"in% res&lt:
/o&ses on t#e material flo"
prior to t#e point of reeipt.
A s!n#ronised flo" of material from t#e s&pplier to t#e
point of &se.
+s t#e mar'etplae si6e -ased on t#e deli$er! inter$al from s&pplier, "it#
exeption proesses in plae to mana%e min9max $ariane
5.2.
2
5.2.
3
Are all s&pplier s#ippin% and arrier proesses o$ered -! standardi6ed
"or'
5.2.
4
Does t#e man&fat&rin% apait! s&pport r&n time to meet demand, and
promote small lot si6es
S&pport /&ntions, if &sed orretl! "ill #a$e t#e follo"in%
res&lt:
Prod&tion Control mana%e
t#e s!n#ronised material
flo" t#ro&%#o&t t#e s&ppl!
#ain. Pa'a%in% s&pport t#e
material flo" strate%! and
lin' to ne" prod&ts.
Demand "ill -e smoot#ed allo"in% a-normalities to -e
mana%ed "it#in safet! sto' le$els.
5.3.
2
5.3.
3
1#/22 234265807.xls
Plant/ Cell9 oo
%ust&'n&Time Section9 /
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
?ne a le$el of sta-ilit! #as -een a#ie$ed in t#e prod&tion proesses t#e or%anisation an -e%in red&in% in$entor! of in proess and ra" materials. 2#e aim is to #a$e t#e Fri%#t *&antit!G of t#e
Fri%#t partG in t#e Fri%#t plaeG at t#e Fri%#t timeG.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
15/22 234265807.xls
Plant/ Cell9 oo
%ust&'n&Time Section9 /
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
?ne a le$el of sta-ilit! #as -een a#ie$ed in t#e prod&tion proesses t#e or%anisation an -e%in red&in% in$entor! of in proess and ra" materials. 2#e aim is to #a$e t#e Fri%#t *&antit!G of t#e
Fri%#t partG in t#e Fri%#t plaeG at t#e Fri%#t timeG.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
/.5 One piece flo0
/.5.1 Does t#e la!o&t promote prod&t flo" or small lot prod&tion < = N/A 0a!o&t, if performed orretl!, "ill #a$e t#e follo"in% res&lt:
X
>
/.5.2 < = N/A Score 9 /.5 One piece flo0
X
5.4.( 0a!o&t promotes prod&t flo"
/.5.# Are ma#ines or%anised in ell la!o&t, promotin% flexi-le mannin% < = N/A >*&ipment9ma#iner! apa-le of mo$in%
X
1a#ines or%anised in ell la!o&t
/.5.5 +s t#e la!o&t desi%ned aro&nd peoples mo$ements and er%onomis < = N/A 0a!o&t desi%ned aro&nd people
X
0a!o&t allo"s for ease of maintenane
/.5./ Does t#e la!o&t allo" for ease of maintenane, and replenis#ment of parts < = N/A 0a!o&t ens&res %eo%rap#ial f&ll "or' s!stem
X
la!o&t enfores /+/?
/.5.$ < = N/A Total
X Ma!
? N/A
/.5.7 Are all man&fat&rin% -&ffers se*&ential "it# t#e la!o&t enforin% /+/? < = N/A
X
Total
Ma!
? N/A
0a!o&t of a prod&tion ell is a prime opport&nit! to eliminate "aste from t#e prod&tion s!stem one and for all. ;! fo&sin% on de$elopin% a la!o&t t#at promotes flexi-ilit!, and t#e exl&sion of t#e 7
"astes, an en%ineer or prod&tion s&per$isor an a#ie$e t"o important t#in%s: (. 2#e optim&m la!o&t for a#ie$in% prod&tion tar%ets. 2. +mpro$ement of morale in t#e team.
> A prod&tion line9ell "#i# pre$ents "aste from
o&rrin%. +.e. no room for o$erprod&tion
A lean la!o&t an eliminate
"aste and pre$ent re7
o&rrene -! defa&lt.
+s t#e la!o&t of e*&ipment and ma#iner! apa-le of mo$in% to aommodate
#an%es in demand
5.4.
2
5.4.
3
5.4.
4
5.4.
5
5.4.
6
5.4.
7
Does t#e la!o&t ens&re a %eo%rap#ial f&ll "or' s!stem, promotin% pro-lem
identifiation and esalation
%ust&'n&Time
Section
1//22 234265807.xls
Plant/ Cell9 oo
%ust&'n&Time Section9 /
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
?ne a le$el of sta-ilit! #as -een a#ie$ed in t#e prod&tion proesses t#e or%anisation an -e%in red&in% in$entor! of in proess and ra" materials. 2#e aim is to #a$e t#e Fri%#t *&antit!G of t#e
Fri%#t partG in t#e Fri%#t plaeG at t#e Fri%#t timeG.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
1$/22
234265807.xls
Plant/ Cell9 oo
%i(o)a *+uilt in ,ualit-. Section9 $
Assessment No9 oo
:ate9 oo
Assessor9 oo
Su+;ect 6uestion <esult
$.1 An(on
$.1.1 < = N/A Andon, if applied orretl! "ill #a$e t#e follo"in% res&lt:
X
>
$.1.2 Are $is&al and a&di-le si%nals assi%ned to ea# %ro&p9ma#ine < = N/A
X Score 9 $.1 An(on
6.(.( Andon all -&ttons or ords
$.1.# < = N/A
X 6.(.2 .is&al and a&di-le si%nals
6.(.3 Pro-lem and Co&ntermeas&re
$.1.5 < = N/A
X 6.(.4 ,or' !le indiator
6.(.5 Andon esalation proed&re
$.1./ +s an Andon esalation proed&re e$ident in t#e "or' area < = N/A
X 6.(.6 )espond and assess
6.(.7 /ixed Position Stop
$.1.$ < = N/A
X 6.(.8 1ana%ement re$ie"in% Andon
$.1.7 +s fixed position stop f&ntionallit! -&ilt into t#e prod&tion s!stem. < = N/A
X
$.1.@ < = N/A
X
Total
Ma!
? N/A
Hido'a 4-&ilt in *&alit!5 is t#e appliation of t#e *&alit! priniple FDonBt )eei$e DonBt 1a'e and DonBt Pass DefetsG. +t applies e*&all! to e*&ipment and a&tomated proesses as it does to man&al
prod&tion proesses. 2#e *&alit! priniple is s&pported in t#e man&fat&rin% proesses -! allo"in% time "it#in t#e 2a't 2ime al&lation for pro-lems to -e resol$ed.
Are Andon all -&ttons or ords in plae ad@aent to prod&tion operators.
A&tomati detetion and alert s!stem for prod&tion e*&ipment
+t "ill $is&all! demonstrate t#e ommitment #i%#li%#tin%
and resol$in% pro-lem "#ilst maintainin% prod&tion
$ol&mes and satisf!in% &stomer demand.
Hapanese for 0antern, t#e
andon s!stem allo"s pro-lems
to -e raised and responded
to "it#in t#e prod&tion
!le.
>
+s a pro-lem and o&ntermeas&re proess in plae to tra' and resol$e
iss&es raised
,#at me#anisms do operators #a$e to reo%nise t#at t#e! are -e#ind "it#
t#eir "or' !le
Are t#e dediated s&pport mem-ers a-le to respond and assess pro-lems in
a timel! manner 4E of tar%et !le time5
Are mana%ement &sin% Andon data to identif! -ottlene's and to impro$e
t#em
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
17/22
234265807.xls
Plant/ Cell9 oo
%i(o)a *+uilt in ,ualit-. Section9 $
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
Hido'a 4-&ilt in *&alit!5 is t#e appliation of t#e *&alit! priniple FDonBt )eei$e DonBt 1a'e and DonBt Pass DefetsG. +t applies e*&all! to e*&ipment and a&tomated proesses as it does to man&al
prod&tion proesses. 2#e *&alit! priniple is s&pported in t#e man&fat&rin% proesses -! allo"in% time "it#in t#e 2a't 2ime al&lation for pro-lems to -e resol$ed.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
$.2 Po)a 2o)e
$.2.1 < = N/A Po'a Io'e, if &sed orretl! "ill #a$e t#e follo"in% res&lt:
X
> Prod&tion "it# 6ero defets
$.2.2 Are Po'a Io'e de$ies #e'ed at t#e start and end of s#ift < = N/A
X Score 9 $.2 Po)a 2o)e
6.2.( 2eams an s#o" li$e examples of P. Io'e
Po'a Io'e de$ies are #e'ed
$.2.# < = N/A 2eams stri$e to implement #an%es
X 1an&fat&rin% and desi%n en%ineers
Total
$.2.5 < = N/A Ma!
X ? N/A
$.# 3ull 4or) S-stem
$.#.1 Are -&ffers de7o&pled and independent < = N/A
X >
> Pre$ent ?$er7prod&tion
$.#.2 < = N/A
X Score 9 $.# 3ull 4or) S-stem
6.3.( ;&ffers de7o&pled and independent
?perated on a /+/? -asis
$.#.# ,#at met#ods are &sed to al&late -&ffer si6es, inl&din% min9max < = N/A ;&ffer si6es al&lated
X
Total
Ma!
? N/A
Total
Ma!
? N/A
Can teams s#o" li$e examples of Po'a Io'e de$ies t#at t#e! #a$e
implemented on e*&ipment, toolin% and assem-l! proesses
Po'a !o'e 4mista'e proofin%5
is a met#odolo%! for
a#ie$in% 6ero defets.
6.2.
2
Do teams stri$e to implement #an%es t#at eliminate defets rat#er t#an
pre$ent or detet
6.2.
3
6.2.
4
Do man&fat&rin% and desi%n en%ineers eno&ra%e feed-a' from
prod&tion, and -&ild de$ies or #an%es into f&t&re pro%rammes
/&ll ,or' S!stem, if &sed orretl! "ill #a$e t#e follo"in%
res&lt:
Allo" t#e ma&fat&rin% proess to smoot# pro-lems
-et"een se*&ential prod&tion operations.
Desi%nated -&ffers to
s&pport t#e operation of
Andon.
Are all desi%nated -&ffers operated on a /+/? -asis t#ro&%#o&t t#e
se*&ene
6.3.
2
6.3.
3
%i(o)a
Section
1@/22 234265807.xls
Plant/ Cell9 oo
People Section9 7
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
7.1.1 < = N/A
X >
>
7.1.2 Do all mana%ers s&pport str&t&red pro-lem sol$in% < = N/A
X
Score 9 7.1 Continuous improvement Culture
7.(.(
7.1.# Do people ta'e o"ners#ip of onerns and lead impro$ement ati$ities < = N/A
X 7.(.2 All mana%ers s&pport pro-lem sol$in%
7.(.3 ?peratin% teams empo"ered
7.1.5 < = N/A
X 7.(.4 Contin&o&s impro$ement pro%ression poli!
7.(.5 Contin&o&s impro$ement &lt&re s&stained
7.1./ < = N/A
X Total
Ma!
? N/A
7.2 Organi"ation
7.2.1 < = N/A
X >
7.2.2 < = N/A Score 9 7.2 Organi"ation
X 7.2.( 1&lti7s'illed teams
Dediated s&pport
Total
Ma!
? N/A
0ean 1an&fat&rin% is a olletion of tools, te#ni*&es and p#ilosop#ies, all of "#i# re*&ire people to ens&re t#eir s&ess "it#in a ompan!. 8one of t#e tools assessed so far an operate in isolation
and need t#e onstant $i%ilane and s&pport of t#e mana%ement team and operatin% teams to %ain t#e -enefits. 2#e 0ean 1an&fat&rin% s!stem is t#ere for a p&rpose: t#e elimination of "aste to
red&e ost. /or t#e s!stem to "or' effeti$el!, ea# of t#ese tools and onepts "ill #a$e -een desi%ned and implemented "it# t#e f&ll s&pport of t#e mana%ement team, t#e sponsors of 0ean.
7.1 Continuous
improvement Culture
Do all mana%ers ati$el! s&pport ontin&o&s impro$ement ati$ities, "it# a
fo&s on impro$ements t#at an -e done -! t#e %ro&ps
A lean C&lt&re "ill #a$e t#e follo"in% res&lt:
A diret impat on prod&t ost !ear7on7!ear t#ro&%# t#e
elimination of "aste
An en$ironment "#i# allo"s
ideas, diretl! lin'ed to t#e
elimination of "aste, to
-eome realit! and
implemented -! t#e teams.
>mpo"ered operatin% teams, "illin% to ontri-&te to t#e
s&ess of t#e ompan!
1ana%ers ati$el! s&pport Contin&o&s impro$ement
ati$ities
3o" does t#e ompan! reo%nise and promote people t#at ontri-&te to t#e
ontin&o&s impro$ement &lt&re
,#at means are &sed to stim&late and s&stain a ontino&s impro$ement
&lt&re
,#at m&lti7s'illed s&pport teams are in plae to s&pport impro$ement
ati$ities
A lean or%anisation "ill:
Pro$ide t#e teams "it# t#e le$el of s&pport re*&ired to
maintain prod&tion $ol&mes and ass&re *&alit!.
2#e ompan! #as a str&t&re
in plae "#i# promotes t#e
ser$ie of $al&e addin% and
t#e elimination of "aste.
Does t#e prod&tion area #a$e dediated s&pport mem-ers to ens&re -&ilt in
*&alit! and maintenane of t#e prod&tion performane
7.2.
2
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
1A/22 234265807.xls
Plant/ Cell9 oo
People Section9 7
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
0ean 1an&fat&rin% is a olletion of tools, te#ni*&es and p#ilosop#ies, all of "#i# re*&ire people to ens&re t#eir s&ess "it#in a ompan!. 8one of t#e tools assessed so far an operate in isolation
and need t#e onstant $i%ilane and s&pport of t#e mana%ement team and operatin% teams to %ain t#e -enefits. 2#e 0ean 1an&fat&rin% s!stem is t#ere for a p&rpose: t#e elimination of "aste to
red&e ost. /or t#e s!stem to "or' effeti$el!, ea# of t#ese tools and onepts "ill #a$e -een desi%ned and implemented "it# t#e f&ll s&pport of t#e mana%ement team, t#e sponsors of 0ean.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
2/22 234265807.xls
Plant/ Cell9 oo
People Section9 7
Assessment No9 oo
:ate9 oo
Assessor9
oo
Su+;ect 6uestion <esult
0ean 1an&fat&rin% is a olletion of tools, te#ni*&es and p#ilosop#ies, all of "#i# re*&ire people to ens&re t#eir s&ess "it#in a ompan!. 8one of t#e tools assessed so far an operate in isolation
and need t#e onstant $i%ilane and s&pport of t#e mana%ement team and operatin% teams to %ain t#e -enefits. 2#e 0ean 1an&fat&rin% s!stem is t#ere for a p&rpose: t#e elimination of "aste to
red&e ost. /or t#e s!stem to "or' effeti$el!, ea# of t#ese tools and onepts "ill #a$e -een desi%ned and implemented "it# t#e f&ll s&pport of t#e mana%ement team, t#e sponsors of 0ean.
) 77 8ot started9inomplete
: 77 Complete
; 77 8ot Applia-le
7.#.1 < = N/A
X
>
7.#.2 < = N/A Score 9 7.# Performance Management
X
7.3.( S#ort and lon% term $ision
7.#.# < = N/A <e! Performane +ndiators 4<P+s5 defined
X
<P+s $s personal performane
7.#.5 Are mana%ement appraised &sin% t#e 360 de%ree assessment riteria < = N/A 360 de%ree assessment
X
2rainin% in performane mana%ement
7.#./ < = N/A <P+ -ased pro%ression
X
Total
Ma!
7.#.$ < = N/A ? N/A
X
Total
Ma!
? N/A
7.# Performance
Management
Does t#e ompan! #a$e a s#ort and lon% term $ision -ased on lear
meas&ra-les 4!earl! plan, 5 !earl! plan5
Performane 1ana%ement, if performed orretl!, "ill #a$e
t#e follo"in% res&lt:
A#ie$in% t#e $ision t#ro&%#
t#e meas&red deplo!ment of
o-@eti$es.
A#ie$e %oals t#ro&%# meas&red deplo!ment of
o-@eti$es
<e! Performane +ndiators 4<P+s5 are defined -! t#e mana%ement team
"it# lear tar%ets. 2#ese are t#en asaded t#o&%#o&t t#e or%anisation
+s t#ere a diret lin' -et"een res&lts a#ie$ed &sin% <P+s and personal
performane of t#e mana%ement team
7.3.
2
7.3.
3
7.3.
4
7.3.
5
Does t#e mana%ement team #a$e a f&ll &nderstandin% of t#e <P+, inl&din%:
-a'%ro&nd, tar%ets, meas&rement riteria, timin%..
7.3.
6
+s t#e pro%ression poli! 4rem&neration9promotion5 -ased on t#e
performane res&lt from t#e <P+s
People
Section
2(922 234265807.xls
Plant: oo
:epartment :etail
Cell: oo
Date: oo
Assessor: oo


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(.(.( )ele$ant tools, parts, e*&ipment, in speified loations n9a
(.(.2 5S *&arantine area f&ntionin% n9a
(.(.3 ,al'"a!s leared of o-str&tions n9a
(.(.4 Cleanin% s#ed&le a$aila-le n9a
(.(.5 Cleanin% standards $isi-le and desripti$e n9a
(.(.6 A&dits and ation plans e$ident n9a
(.(.7 All emplo!ees #ad a"areness trainin% n9a
(.2.( 2eam -oards "it# <P+ n9a
(.2.2 .is&al one point lessons n9a
(.2.3 A&dit s#eets &p to date n9a
(.2.4 Central information area "it# <P+ n9a
(.3.( .is&al mar'in%s n9a
(.3.2 De$iations to esta-lis#ed standards n9a
(.3.3 .is&al ontrol 4<amis#i-ai5 s!stem n9a
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2.(.( All prod&tion = non prod&tion proesses n9a
2.(.2 ,or' element s#eets n9a
2.(.3 Created -! t#e team mem-ers n9a
2.(.4 .al&e added 9 non $al&e added n9a
2.(.5 ,or' -alane -oard n9a
2.(.6 )e%&lar a&dits n9a
2.(.7 2rain "it# standard "or' n9a
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2.2.2 2a't time is re$ie"ed periodiall! n9a
2.2.3 Std "or' and -alane #arts are re$ie"ed n9a
2.2.4 1in7max le$els re$ie"ed "it# ta't n9a
2.2.5 Prod&tion performane monitored n9a
2.2.6 Prod&tion performane data &sed n9a
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3.(.2 S#in%oLs 5 step met#odolo%! and "all #art n9a
3.(.3 1&lti7disiplined teams n9a
3.(.4 (st off inspetion apa-ilit! n9a
3.(.5 All %a&%es and tools are stored ad@aent n9a
3.(.6 Standard "or' s#eets n9a
3.(.7 1ana%ement sponsor ideas and deplo!ment n9a
3.(.8 1ana%ement re$ie" #an%eo$er n9a
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4.(.( 5 Steps of a&tomomo&s maintenane n9a
4.(.2 2a% mana%ement s!stem n9a
4.(.3 .is&al ontrol 4<amis#i-ai5 s!stem n9a
4.(.4 <e! maintenane lin'ed to andon n9a
4.(.5 S'ills matrix n9a
4.(.6 A&alit! parameters &nderstood n9a
4.(.7 ?>> o"ned -! teams n9a
4.2.( Central master s#ed&le n9a
4.2.2 1ean time -et"een fail&res n9a
4.2.3 1ean time to repair n9a
4.2.4 P1 ati$ities inl&de operatin% teams n9a
4.2.5 Pre$enti$e maintenane n9a
4.2.6 P1 team assist in pro-lem sol$in% n9a
4.2.7 /re*&ent and lon% do"ntime -rea'do"ns 'no"n n9a
4
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4.3.2 Constraint ma#ine n9a
4.3.3 Performane speed of e*&ipment n9a
4.3.4 ,ee'l! meetin%s are #eld -! teams n9a
4.4.( >*&ipment trainin% n9a
4.4.2 2eam -ased pro-lem sol$in% n9a
4.4.3 2P1 A"areness trainin% n9a
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22922 234265807.xls
Plant: oo
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Cell: oo
Date: oo
Assessor: oo


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5.(.( Point of &se min7max le$els n9a
5.(.2 Card and all s!stems n9a
5.(.3 Desi%nated footprint si6es n9a
5.(.4 +n proess prod&tion9 prod&tion se*&ene n9a
5.(.5 >xeption proesses n9a
5.(.6 0oation #an%e proesses n9a
5.(.7 Deli$er! fre*&en! and pa' &tilisation n9a
5.(.8 Co$ered -! standardi6ed "or' n9a
5.2.( 2ime slotted material olletion n9a
5.2.2 2ime slotted reei$in% proesses n9a
5.2.3 1ar'etplae si6ed "it# exeptions n9a
5.2.4 Standardi6ed "or' n9a
5.3.( Capait!9small lot si6es n9a
5.3.2 Prod&tion s#ed&led -! &stomer demand n9a
5.3.3 Pa'a%in% poli! n9a
5.4.( 0a!o&t promotes prod&t flo" n9a
5.4.2 >*&ipment9ma#iner! apa-le of mo$in% n9a
5.4.3 1a#ines or%ani6ed in ell la!o&t n9a
5.4.4 0a!o&t desi%ned aro&nd people n9a
5.4.5 0a!o&t allo"s for ease of maintenane n9a
5.4.6 0a!o&t ens&res %eo%rap#ial f&ll "or' s!stem n9a
5.4.7 la!o&t enfores /+/? n9a
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6.(.2 .is&al and a&di-le si%nals n9a
6.(.3 Pro-lem and o&ntermeas&re n9a
6.(.4 ,or' !le indiator n9a
6.(.5 Andon esalation proed&re n9a
6.(.6 )espond and assess n9a
6.(.7 /ixed position stop n9a
6.(.8 1ana%ement re$ie"in% Andon n9a
6.2.( 2eams an s#o" li$e examples of Po'a Io'e n9a
6.2.2 Po'a Io'e de$ies are #e'ed n9a
6.2.3 2eams stri$e to implement #an%es n9a
6.2.4 1an&fat&rin% and desi%n en%ineers n9a
6.3.( ;&ffers de7o&pled and independent n9a
6.3.2 ?perated on a /+/? -asis n9a
6.3.3 ;&ffer si6es al&lated n9a
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7.(.2 All mana%ers s&pport pro-lem sol$in% n9a
7.(.3 ?peratin% teams empo"ered n9a
7.(.4 Contin&o&s impro$ement pro%ression poli! n9a
7.(.5 Contin&o&s impro$ement &lt&re s&stained n9a
7.2.( 1&lti7s'illed teams n9a
7.2.2 Dediated s&pport n9a
7.3.( S#ort and lon% term $ision n9a
7.3.2 <e! Performane +ndiators 4<P+s5 defined n9a
7.3.3 <P+s $s personal performane n9a
7.3.4 360 de%ree assessment n9a
7.3.5 2rainin% in performane mana%ement n9a
7.3.6 <P+ -ased pro%ression n9a
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? 8&m-er of N?N 4n 9 a5 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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