utilizing sirm (short interval results management) and...
Post on 23-Jul-2018
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Utilizing SIRM (Short Interval Results Management) and
Technology to Make Better Real Time
Decisions
Presented By: Ariel Beegle and Rodrigo Cantu
What is SIRM?
Short interval results management (SIRM) is a process for identifying and acting on opportunities to improve production
Quick and focused review of performance Show expected vs. actual performance Use of lean tools throughout the day to identify root causes and address corrective action At the end of the day, SIRM is just a report – its what you do with it that is so powerful!!
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SIRM Implementation Plan
1. Identify pilot area Line Constraint Where the rubber meets the road
2. Identify loss metrics OEE (Overall Equipment Effectiveness)
Six losses and downtime reasons
PPPH, UPPH (for highly labor oriented processes) Yield by hour (for process that suffers heavy yield losses)
3. Figure out how to get information Photo eye, Counter on machine, scale for weights
4. Create visual board / tracking tool Create a simple way of tracking the data Printed form, spreadsheet, whiteboard, flip chart, etc.
3
SIRM Implementation Plan
5. Train team and start review meetings Review SIRM Training and where to get the necessary information Decide what metrics spur a huddle (below 90% to budget?) Team Leader demonstrates process to the team and does SIRM reviews for the first week- create benchmark for team Operations and Facility leaders provide coaching as needed for discussion
6. Sustain progress through audits Intent is to identify and reinforce great behavior Operations and Facility leaders should audit teams at least weekly through production walks, gemba walks, etc.
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SIRM Process
The SIRM process repeats cycles of identifying and then implementing effective actions to improve performance
Last Hour
5
Now Next Hour
Best practices for SIRM Huddles
Huddles are 5 minute reviews of the board every hour when opportunities come up. Gather all available Partners for the huddle
Lead operator / production specialist Maintenance technician Team leader Quality & Sanitation (if needed)
All Partners are able to take direct action on the manufacturing process Remember to use the 5 why’s to find root cause of opportunities and document the root cause and corrective actions on the board.
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SIRM Board Visual Examples
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5:30 18oz Vanilla 2 1 1,086 541 No Mix; Partner didn’t hear page Increase vol of page in whse
6:30 18oz Vanilla 4 3 1,086 1,390
7:30 18oz Vanilla 6 6 1,086 1,400
9:30 18oz Vanilla 8 8 1,086 1,125 10:30 18oz Vanilla 10 9 1,086 682 stopped for lunch; 2 call ins
11:30 18oz Vanilla 12 11 1,086 1,084
12:30 18oz Lemon 2 1 1,800 1,366 changeover + 15 min maint fixed broken infeed
23 22 13,716 13,382
2:30 18oz Lemon 11 10 1,800 1,492 burnt cakes; oven override adjusted oven
1:30 18oz Lemon 8 8 1,800 2,197
Challenges
Improve manufacturing productivity
Gather actionable shop floor information
Expose problem areas
Inspire and motivate Partners
Information fast – and at fingertips
Solution
• XL800 Productivity Appliance™
• Snaps on to existing processes
• Delivers real-time performance data to all levels
• Web-based interface
Strategic – Analytics Tactical – Live Reports Operational – Scoreboard
“Six-in-One”
Visual Display Instant performance feedback
Production Monitor Plug-and-play process integration
Data Warehouse 100+ KPIs, 1,000 shifts, 1,000 jobs
I/O Processor Digital inputs, outputs and communication ports
Embedded Server Download to Excel, documentation center
Programming Platform Unlimited applications
Downtime Reason Code
Operator Scans Downtime Reason barcode
Instead of this … • START • STOP • LOST TIME • REASON
Reading the Board
Job Display Resets by Job
Target based on Takt Time
Actual based on Photo-eye
Efficiency = Actual / Target
Downtime for Job
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