bb wk1 190 lean performance metrics
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8/22/2019 Bb Wk1 190 Lean Performance Metrics
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Black Belt Training Ford Proprietary
Copyright © 2005-2006, Ford Motor Company – All Rights Reserved
Lean Performance
Metrics
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Lean Performance Metrics
Black Belt Training Slide 2
Module Objectives
By the end of this module, the participant will be able to :
Understand the importance of Lean Performance Metrics in identifying
waste and measuring successful progress on our Lean journey.
Define, calculate, and explain why Lean Performance Metrics are
used:• The two types of measurables
• First Time Through
• Dock-to-Dock
• Build-to-Schedule• Overall Equipment Effectiveness
• Total Cost
• SHARP and
• Attitude Surveys
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Lean Performance Metrics
Black Belt Training Slide 3
The FPSMeasurables were
designed to help
plants, individualoperations, and
work groups assess
their performance
FPS Measurables
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Lean Performance Metrics
Black Belt Training Slide 4
Two Types of Measurables
Manufacturing Measurables
First Time Through (FTT)
Dock-to-Dock (DTD)
Build-to-Schedule (BTS)
Overall Equipment Effectiveness (OEE)
Total Cost (TC)
Work Group Issues
SHARP
Attitude Surveys
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Lean Performance Metrics
Black Belt Training Slide 5
FTT is the percentage of units processed at theEvaluation Point that meet Quality Guidelines
the first time without being repaired, retested,
returned from within the plant, or scrapped.
First Time Through (FTT)
Total Units Processed - Units Not OK
Total Units ProcessedFTT @ an EP = X 100 %
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Lean Performance Metrics
Black Belt Training Slide 6
Dock-to-Dock Time is theelapsed time between theunloading of rawmaterials and the releaseof the finished goods for shipment
Dock-to-Dock (DTD)
PRODUCTION DTD = Inventory (Control Part)
End of Line Rate
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Lean Performance Metrics
Black Belt Training Slide 7
BTS is the percentage of products scheduled for a given day
that are produced on that day in the right sequence
Build-to-Schedule (BTS)
BTS % = % Volume x % Mix x %Sequence
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Lean Performance Metrics
Black Belt Training Slide 8
OEE is a measure of the abilityof a piece of equipment or aprocess to consistently produceproducts which meet Quality
Guidelines without disruption atthe designated cycle rate
Overall Equipment Effectiveness (OEE)
OEE = Availability X Performance Efficiency X Quality Rate
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Lean Performance Metrics
Black Belt Training Slide 9
Total Cost (TC)
Total Cost measures total cost per unit
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Lean Performance Metrics
Black Belt Training Slide 10
SHARP is a detailed, quantitative evaluation that emphasizesproactive improvements in health and safety processes
Safety and Health Assessment Review Process
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Lean Performance Metrics
Black Belt Training Slide 11
Attitude Surveysmeasure employeeattitudes about their jobs and conditions in
the work environment
Attitude Surveys
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Lean Performance Metrics
Black Belt Training Slide 12
How are Measurables used?
Plants use measurables to: Analyze trends
Solve problems
Verify results
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Lean Performance Metrics
Black Belt Training Slide 13
Objectives Review
The participant should be able to:
Explain the importance of Lean Performance Metrics in identifyingwaste and measuring successful progress on our Lean journey.
Define, calculate, and explain why Lean Performance Metrics areused:
• The two types of measurables
• First Time Through
• Dock-to-Dock
• Build-to-Schedule
• Overall Equipment Effectiveness• Total Cost
• SHARP and
• Attitude Surveys
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