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Quick Plant Assessment

Operations Management

Group 14:
Aayush Sunil Kabra (PGP18091) |
Anurag Belash Thirkey (PGP18100) | Chetan (PGP18113)
Dimitri Paul (PGP18116) | Amrut Hutagikar (PGP18270)
Exercise Overview
The exercise is designed to support a plant tour event.
A set of questionnaire for Quick Plant Assessment
The questionnaire is focussed on the leanness of the manufacturing plant.
There are 20 questions in the questionnaire, divided into many categories(i.e
customer focus, safety, cleanliness, visual management/scheduling etc.)
Based on the answers(Yes/No), we finally have to find the ratio of Yes’s to number
of relevant category questions.
About the Sugarcane seed…
Quick Assessment Questionnaire
S.No. Questions
Yes / No
Are visitors welcome to the plant and given information about how the plant operates, the workforce,
1 Yes
customers, and products?

2 Yes
Are ratings for product quality and customer satisfaction displayed for the workforce and customers to view?
3 Is the plant clean, orderly, and well lit? Is the air quality good, and are noise levels low? Yes
Is a visual labeling system used to identify inventory locations, storage places for tools, process areas, and
4 Yes
movement lanes?
5 Does it appear that everything has a specific place, and everything is stored in its place? Yes
6 Are performance measures and goals for these measures prominently posted and up to date? Yes
Are production materials brought to and stored near where they are used rather than in separate remote
7 No
storage areas?

8 Are specific instructions for how work is to be done and quality specifications visible at all workstations? Yes

9 Are up to date charts that show productivity, quality, and safety visible in all process areas? No

10 Is each process area scheduled using some type of pacing mechanism so workers can see real-time status No
against the schedule?
Quick Assessment Questionnaire
S.No. Questions
Yes / No
Can the current state of the plant be viewed from a central control room, on a status board, or online
11 No
computer display?

12 Is material moved only once and as short a distance as possible? Is material moved efficiently in appropriate Yes
containers?
13 Is the plant laid out in continuous product line flows rather than in "shops"? No
Are workers organized in teams and are they trained and empowered to engage in problem solving and
14 Yes
ongoing improvements?
15 Do employees seem committed to continuously improving processes? Yes
16 Is there a formal plan for equipment preventive maintenance and improvement of tools and processes? Yes
17 Is there a process for managing projects (especially new product start-ups), with cost and timing goals? No
Is there a supplier certification process with measures for delivery, cost, and quality performance? Are these
18 Yes
measures shared with suppliers frequently?
19 Are fail-safe methods used in the processes to prevent common product quality problems? Yes
20 Would you buy the products this plant produces? Yes
QPA Score Sheet
No. of Yes's to No.
No. of Number of
Assessment category Questions of Relevent
Question Yes's
Question

Customer focus 1, 2, 20 3 3 1:1


Safety, cleanliness, and order 3, 4, 5, 20 4 4 1:1
2, 4, 6, 7, 8, 9, 10, 11,
9 5
Visual management/Scheduling 20 5:9
Use of space, movement efficiency, and 7, 12, 13, 20 4 2
product line flow 1:2
Teamwork 9, 14, 15, 20 4 3 3:4
Maintenance of equipment 16, 20 2 2 1:1

8, 17, 20 3 2
Management of complexity and variability 2:3
Supply chain integration 18, 20 2 2 1:1
Quality commitment 8, 9, 15, 17, 19, 20 6 4 2:3

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