20170124 creating a continuous improvement master plan ... · 1/24/2017 · the 3 critical parts...
TRANSCRIPT
People Development focusedPresentation by:
Ross KennedyPresident CTPM Free Webinar 45President CTPM
24 January 2017
Free Webinar 45
C ti C ti I tCreating a Continuous Improvement Master Plan for the year aheadMaster Plan for the year ahead
Outline of Presentation1. Understanding the Critical Parts of a CI Master Plan2 Determining the Focus of your CI activities
Outline of Presentation
2. Determining the Focus of your CI activities3. Creating a CI Master Plan Template for your site4 Managing the CI Master Plan
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
4. Managing the CI Master Plan
Why have a Master Plan?
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
Why progress a TPM & Lean / CI Journey
Example Key Success Factors for Operations
‘Cause’ Key Success Factors
Plant &Safet & C tQualityPerformance
InventoryPerformance
Plant & EquipmentPerformance
PeoplePerformance
Safety &EnvironmentPerformance
SupplierPerformance
CustomerSatisfactionPerformance
Cost / FinancialPerformance
‘Effect’ Key Success Factor
Performance measures should be grouped under the appropriate Key Success Factor
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
Performance measures should be grouped under the appropriate Key Success Factor
How to focus a TPM & Lean / CI Journey
The need for ‘Drivers’ to focus Activities
Equipment Focused (TPM) Process Focused (Lean)
Overall Equipment Effectiveness L d TiOverall Equipment Effectiveness(7 Losses)
Lead Time(7 Wastes)
C l I L lCorrelates to Good Output Correlates to Inventory LevelsCorrelates to Good Output
ld i Values StreamsProduction Areas
Production Support Areas
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
pp
Key Components of a TPM & Lean / CI Journey
Company ValuesValues
OperatorReliability Employee
Engagement
Lead Time Reduction
AutomatedQuality &Principles y
TPM Engagement& FLOWy
Visual Mgmtp
ErrorProof
StdWork SPCMethods 5S SMED Pull RCA
Tools
Activities& Focus
Cross-functional Teams Area Based Teams Projects Events
Production Production Support Value Streams People Dev
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
Adapted from: This is Lean: Niklas Modig and Par Ahlstrom – Sweden 2015
Activities
Addressing losses / wastes from both ends of the Pareto ChartArea Based Teams:Cross functional Teams: Area Based Teams:Focus on ‘Prevention at Source’ (equipment defects and everything that is
Cross-functional Teams:Identify the big losses / wastes and try to find the best solution
not right – small little losses / wastes), recognising that the big losses / wastes will also reduce and become easier to solve
Technical Issues focus
30People Development focus
20%
LossCheck – expose equipment defectsAct – fix equipment defectsPlan / Standardise checklists etc
10
0
Loss Plan / Standardise – checklists etcDo – regular monitoring to sustain
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
0
Reasons for Loss / Waste
How Long should we plan out to?
Key Finding from Joel Barker’s study on what makes
Those with the longest time perspective are the most successful
People, Companies and Countries successful or winners:
Those with the longest time perspective are the most successful
5 year Master Plan showing how CI will be cascaded across site
1 year Annual Plan showing more detail including shifts involved
4 month Cycle Plan or Schedule showing weekly activities4 month Cycle Plan or Schedule showing weekly activities
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
1. Understanding the Critical Parts of a CI Master Plan
1. Education & Training
2. Reactive Improvement
3 People Development3. People Development
4. Value Stream focused Pro-active Improvement
5. Production focused Pro-active Improvement
6 Production Support focused Pro active Improvement6. Production Support focused Pro-active Improvement
7. Site Processes focused Pro-active Improvement
8. Leadership activities
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
The 3 Critical Parts of a Continuous Improvement Strategy2. Determining the Focus of your CI activities
p gy
World Class 3 P ti I t ( t d )
Improvement VisionOperational Excellence3. Pro-active Improvement (steady)
How do we increase capability by reducingor eliminating losses and wastes through technology,
pWorld Class / True North / Perfection
ance
projects & events and on-going improvement
rfor
ma
Budget / Expectation?
Pe Incident reported at Daily Review Meeting
1. Reactive Improvement (rapid)How quickly can we get back to Budget / Expectation and stop it happening again
TimeExpectation and stop it happening again
0 2 Stable Production Plan through Flow Logic (urgent)
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
% 2. Stable Production Plan through Flow Logic (urgent)
2. Determining the Focus of your CI activities
1. Reactive Improvement – striving to get back to standard
2. Stable Production Plan – striving to eliminate disruption / fire-fighting
3. Pro-active Improvement – striving for your Improvement Vision
However
Need to remember Jeffrey Liker’s learning about sustaining improvement: p
Need to be organic in our thinking rather than mechanistic
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
O i thi ki i lik
2. Determining the Focus of your CI activities
Organic thinking is like Thermodynamics and Entropy
Entropy can be viewed as the amount of energy in a physical system that is not available to do work.physical system that is not available to do work.
2nd Law of ThermodynamicsEntropy, or disorder, will naturally increase over time
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
3. Creating a CI Master Plan Template for your site
3. Creating a CI Master Plan Template for your site
3. Creating a CI Master Plan Template for your site
3. Creating a CI Master Plan Template for your site
Plan and monitor progress through 3 4 month Cycles
4. Managing the CI Master Plan
Plan and monitor progress through 3 – 4 month Cycles supported by Pre-cycle Strategy Planning Sessions (2 weeks
before end of each Cycle) and weekly review meetingsbefore end of each Cycle) and weekly review meetings.
Urgent / Current B i
5 YearMasterPlan &
PeopleDevelopment
PlanBusiness Priorities
Reflection& Learning
from current C l
Plan & Baseline Analysis Opportunities
SheetCycle
3-4 month Cycle U d d M Pl hi I Vi i
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
Updated Master Plan to achieve Improvement Vision
4. Managing the CI Master Plan
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
How can we help ?
Search for, and join:Continuous Improvement Community of Australasia• Post you questions• Engage in the conversations
Search for:CTPM AustralasiaCTPM Australasia• Share this webinar with a colleague• See all our past free webinars
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
• See all our past free webinars
How can we help ?
Contact either Nelson or myself at CTPM if you would like us to email a copy of the
Excel Spreadsheet used to create a Master Plan, Annual Plan and Cycle Plan
Email: [email protected]@[email protected]@ctpm.org.au
Ph 02 4226 6184Phone: 02 4226 6184Web: www.ctpm.org.au
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
Q ti TiQuestion TimePresentation by:Ross Kennedy
Email: ross kennedy@ctpm org au
President CTPM
Email: [email protected]: 02 4226 6184Web: www ctpm org au
Copyright 2017 CTPM – For further information please refer to: www.ctpm.org.au
Web: www.ctpm.org.au