Documente Academic
Documente Profesional
Documente Cultură
VIDEO
Agenda
Company introduction
Caterpillar Production System (CPS)
Link with Caterpillar Strategy
What is it about ?
Results
450 000
Toyota
Denso
GM
Ford
Emerson
Pella
Deere
IBM
Panasonic
Audi
Kohler
Anheuser Busch
International Paper
KPI process
10
Unused
Creativity /
Capability
Lost opportunities due
to poor safety and an
underutilized workforce
Waiting
Lost time due to
poor product flow
shortages, bottlenecks,
down machines
Defects
Over
Production
Inventory
Production or rework of
out-of-specification parts
Excess
Motion
Over
Processing
Transportation
Wasted movement
made while working
Excess movement of
work-in-process
11
12
Management System
13
QUALITY
PEOPLE
Division
Metrics
Casdade
(PQVC Executive
Scorecard)
Facility
Level
(Service Parts)
Area
Level
(Service Parts)
Inbound &
2010 Caterpillar Logistics Services, Inc.
Outbound
Caterpillar Confidential
VELOCITY
RIF
Ideas per Employee
% Ideas Closed Within 30
Days
EOS Engagement
RIF
Ideas per Employee
% Ideas Closed Within 30
Days
Facility 5S Score
Outbound
Area Errors
Standard Work Conformance
Inbound
Storage Location Accuracy
Standard Work Conformance
Outbound
Shipped Within Standard
Inbound
% of Receipts Posted in
Standard
14
COST
Variable Margin (% of
Plan)
6 Sigma Value Prop
OPACC (% of Plan)
ORONA (% of Plan)
Inbound LPH
Outbound LPH
Global LHP
Outbound
Oubound LPH
Inbound
Inbound LPH
Client
Facility
General Manager
Network
Region
Division
15
FEEDBACK
Process
ProcessImprovement
Improvement
Dialogues
Dialogues
16
PLAN
CHECK
DO
ACT
PLAN what we are going to do. In this step we assess where we are,
where we need to be, why this is important, and plan how to close the gap.
DO: Implement the plan and measure its performance
CHECK: Assess the measurements and report the results
ACT: If you have not accomplished your objective,
go through the cycle again, starting with the Plan step.
17
Daily
Weekly
Monthly
Monthly
Organizational Level
VP
General
Manager
Logistics
Center
Manager
Supervisor/
Team Leader Shift kickoff meeting
Facility Monthly
Performance
Review
Weekly
Management
Team Meeting
Monthly
Team
Meeting
Weekly Team
Meeting
Operators
PQVC Facility
Board
Area Metric
Board
Facility Portfolio
Monthly
Performance Review
18
By Phone: PQVC
Reporting Tool
System Metrics
Process Improvement
Dialogue
Metrics Cascade
People
PEOPLE
QUALITY
VELOCITY
Area /
Section Level
Cell Level
Value
Stream
Level
Facility /
Business
Unit Level
COST
Supply Chain Value
Proposition
Hours per Machine -orExpenses per Hours
Worked -or- Expenses per
Machine Hours
COST Choice 1 / 2 / 3 / 4
OEE at Constraint
Hours per Machine -orExpenses per Hours
Worked -or- Expenses
per Machine Hours
COST Choice 1 / 2 / 3 / 4
20
Team Leader
Supervisor
Manager
People metric:
Supportive
Number of ideas per employee per year
Number of ideas closed within 30 days
21
VP
22
23
DM
Follow-Up
DM
RIW Methodology Core training (if not completed in Prework)
Day 1 Determine Current Standard Work
CPS Tools & Techniques (Spaghetti Mapping, 5S, Hour-by-Hour Charting)
Project Specific Training
Day 2 Measure & Analyze Current Work Process (Current State)
Formulate Process Improvements (Future State)
Refine Future State
Day 3 Simulate Future State
Hands-on Shop-Floor Improvements
Evaluate, Verify, and Refine New Current State
Day 4 Finalize New Standard Process
Establish New Standard Work
Implement 5 Safety and 5 Quality Improvement ideas
MA
AI
IC
24
Four weeks
after the RIW
Standard Work
Audits
25
Cultural System
9 Are we being proactive in Safety?
9 Do we use Customer Feedback for
improvement?
The Cultural System
makes change
possible and
improves the way we
work
26
27
28
Some results
Cat Logistics worldwide PQVC scorecard results (2010 vs 2007):
29
Do
30
Do
9 Underestimate communication
and change management efforts
9 Prepare forever
31
Do
9 Celebrate success
32
33
Questions ?
Miguel Mazarias
General Manager
Caterpillar Logistics Services, Inc
Supply Chain Solutions - EAME Region
2010 Caterpillar Logistics Services, Inc.
Caterpillar Confidential
34