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Skanda Kumarasingam
Introduction
This worksheet was developed by me when I had to improve many production facilities and factories. 2 This integrates the key elements any manager needs to look at before deciding on a method to improve the manufacturing or operating unit. Once you have an overall feel and based on your rating and analysis you will be able to pin-point the key areas for quick and rapid improvement. Using my worksheet you will be able to tour a plant or manufacturing unit, enquire on important and relevant areas from the workers and management and have a report and action plan in no time. Then you can use any of the Japanese or Western operations management techniques to improve the facility. I have used this in my consulting work and as a member of the management teams in many large organizations. They need not be only manufacturing- any operation can benefit when analyzed using this holistic method. The results have been tremendous boost to productivity and profitability. This assessment is the stepping stone to a leaner more efficient organization. This effective worksheet and assessment tool is the result of my 15 years of work in multiple operating units. It is one of the easiest tool any manger or supervisor can lay their hands onto. Please pass it forward to all those who will benefit out of it. I have! Its my gift to you. Skanda Kumarasingam 1st May 2010
Factory Address
Customer Satisfaction
1. 2. 3. 4. 5. 6. 7. Did you see evidence of customer satisfaction ratings and quality certifications & ratings? Did you see records and charts of warranty & product liability costs? Do you think that employee knowledge of external and internal customer requirements was high? Did you see visitor materials and were you and other visitors welcomed? Did employees have knowledge of the market share? Speaking to the employees or management do you think that the rate of new product introduction & acceptance is high? Would you buy the products this operation produces?
Grading is based on the % of Yeses from all the questions asked under this measure Poor Below Average Above Excellent Best in class average average 0-20% 21-40% 41-60% 61-80% 81-99% 100%
Scheduling Systems
1. Was there high degree of scheduling to customer order? 2. Is order process efficiency high? 3. Is product line scheduling originating at single point? 4. Do they use scheduling buckets (each order, hourly, daily, weekly, or monthly)? 5. Is there a supplier scheduling & delivery system in place/seen? 6. Does the operation produce for order fulfillment versus replenishment? 7. Does the operation use Kanban versus computer scheduling? 8. Does the operation use a push versus pull system? 9. Do you think flow time efficiencies were high? 10. Do you think backroom costs of scheduling are low or not evident? 11. Do you think MRP costs are low? 12. Do you think data entry costs are low? 13. Would you buy the products this operation produces?
Grading is based on the % of Yeses from all the questions asked under this measure Poor Below Average Above Excellent Best in class average average 0-20% 21-40% 41-60% 61-80% 81-99% 100%
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Customer Satisfaction Safety, Environment, cleanliness and Order Visual Management Deployment Scheduling Systems Product and Material Flows and Space Use
Inventory and Work in Process Levels People Teamwork, Skill Levels and Motivation 8 Equipment Tooling State and Maintenance 9 Ability to Manage Complexity and Variability 10 Supply Chain Integration 11 Quality Systems Deployment Total (Maximum for Best in Class in All categories =121)