Transcript
4 Process Teams Represent 4 Production plants
instead of Departmental barriers
CHEETA COBRA SMART BLACK EAGLE
Plant Q Plant R Plant S Plant T
Leader Nalin Asanka Dhanuka Mihiruk
Facilitator SAWS CBE GARDG PIR
Member RAJ MN SPCP NCSB
Member SSW DW WACCK LM
Member SS RASR MF SDH
Member CNM SL SPLLG GW
Member NKS
TEAM COMPOSITION -Staff
Position
What is Lean? Which benefits outcome from Lean to us ? Lean Induction for all factory employees with the participation of ICEU members
Start of 2nd LEAN Project Team Started a training program to educate both staff & employees about basic Lean Tools
Start of 2nd LEAN Project Team After the 1st Lean Training, participants were divided in to 10 Lean Teams
Start of 2nd LEAN Project Team Before start main project, Find the solutions for small problems (Abnormalities) identified by the Team members
Mid month Review Meeting (MRM) No. Objective Target Achievement Varience
1 OEE %
1.1 AR %
1.1.1 Total Down time ( hrs.)
1.1.2 Engineering Down time (hrs.)
1.1.3 Other Down time (hrs.)
1.2 PR %
1.3 QR %
1.3.1 D1 %
1.3.2 D2 %
1.3.3 Scrap & Rejects %
1.3.4 Grade II %
1.3.5 Single Hand %
1.3.6 Excess Production %
2 Glove Standards
2.1 Glove Length (no of days out of specs.)
2.2 Glove Thickness (no of days out of specs.)
2.3 Glove Weight (no of days out of specs.)
3 Reserved compound
3.1 Compound Unloaded (kg)
3.2 Compound Blended (kg)
4 Former Breakages
4.1 No of Former Breakages
4.2 No of Craked Formers
5 Kaizen
5.1 No of Kaizen Identified
5.2 No of Kaizen Completed
6 Abnormality
6.1 No of abnormalities identified
6.2 No of abnormalities completed
6.3 No of balance abnormalities to do
7 Last PDT review meeting minutes
8 C & P Projects
Monthly KPIs for MRMAction
No. Objective Target Achievement Varience
3 Reserved compound3.1 Compound Unloaded (kg)
3.2 Compound Blended (kg)
4 Former Breakages
4.1 No of Former Breakages
4.2 No of Craked Formers
5 Kaizen5.1 No of Kaizen Identified
5.2 No of Kaizen Completed
6 Abnormality6.1 No of abnormalities identified
6.2 No of abnormalities completed
6.3 No of balance abnormalities to do
7 Last PDT review meeting minutes
8 C & P Projects
Monthly KPIs for MRMAction
Monthly Operation Excellence Review Opportunity to build up good relationship between staff &
employees
Monthly Operation Excellence Review Opportunity for all employees to exhibit their talents in
front of management & employees
Monthly PDT Review Review the Progress of Month DOS Operation Excellence
program to the Group Top management by Team members
in Every month.
During 2011 & 2012 DOS Operation,
• Implementad 288 Nos. of Kaizens
• Identified 8,460 Abnormalities and
Corrected 7,206 from them
• Thousands of 6S Improvements
• 209 nos. Of Why Why and Fish bone Analysis
• Hundreds of Projects based on 10 Steps Approach directed on PQCDSM improvements
• Create the new “Process approach culture” by changing the departmental bariers based on lean concepts.
Achievements
PDT Status Report….
01 Aug 2012 to 31 Aug 2012
Health Check Up Of
PDT Team
COBRA
(PDT 1) CHEETA
( PDT 2)
SMART
( PDT 3)
BLACK
EAGLE
(PDT 4) Target
No. of Meetings held 23 23 24 24 25/31 Avg. Meeting Attendance % 81.6 87.6 95.0 87.2 90 Abnormality Identified 118 88 104 110 75 Abnormality Eliminated 79 56 80 127 55 No. of Why Why / Fish Bone 04 04 07 03 04 Number of Kaizen Identified 04 04 04 05 04 Number of Kaizen Completed 04 04 04 03 04 OEE Target % 79.22 89.94 82.21 71.16
Actual OEE % 83.73 89.28 79.05 69.72
Factory OEE % 81.29 80.67
• Arrange & conduct monthly assessment & feedback sessions for each PDT members /ADT leaders.
My Job Role – As Executive DOS
Points Priyantha Lakshika Wasantha Bandara Dilhani Lalantha
10 10 5 10 10 10 10
10 8 8 8 8 8 8
10 10 7 8 8 6 8
10 10 7 10 10 6 10
10 10 5 10 10 4 5
10 10 7 10 8 4 6
10 9 8 10 9 5 9
70 67 47 66 63 43 56 0
Buying ability of employees for DOS Journey
Commmitment to the Team
Total
Criteria
Contribution to House keeping walk
Contribution to Abnormality elimination
Active participation in Why Why & Fish Bone Analysis
Ideas given to improve for DOS KPIs.
Leader Ship given to the Team
Ownership & reliability
This score is awarded by the team leader and the DOS Cell coordinator based on
individual's contribution to following criterion.Team member
• Arrange & conduct training programs for new comers & present employees to educate & adapt them in to DOS journey.
My Job Role – As Executive DOS
Monthly 6S Audit
No Section Cobra Cheeta Smart Black Eagle Average S1 S2 S3 S4 S5 S6 Environment Total Average
1 Former 49.3 52.1 67.1 62.1 57.7 5.5 5.0 6.3 7.1 6.6 5.6 4.3 40.4 57.7
2 RMS 35.7 48.6 40.0 44.3 42.1 5.0 4.0 3.3 4.5 3.0 4.8 5.0 29.5 42.1
3 PMS 42.9 40.0 31.4 37.1 37.9 4.0 3.8 2.8 3.5 3.8 3.8 5.0 26.5 37.9
4 QC 31.4 27.1 38.6 35.7 33.2 3.3 4.0 2.0 2.5 2.5 4.0 5.0 23.3 33.2
5 Lab 30.0 30.0 32.9 37.1 32.5 3.3 3.0 0.0 3.0 3.5 5.0 5.0 22.8 32.5
6 FGS 27.1 32.9 28.6 35.7 31.1 2.5 2.8 2.5 3.0 3.0 3.0 5.0 21.8 31.1
7 Engineering 24.3 32.9 30.0 34.3 30.4 3.5 2.8 2.5 3.3 3.3 3.5 2.5 21.3 30.4
8 Dispatch 25.7 31.4 30.0 32.9 30.0 1.8 1.8 1.8 3.0 3.5 4.3 5.0 21.0 30.0
9 Effluent 25.7 35.7 22.9 30.0 28.6 2.5 2.0 3.5 2.0 3.0 2.5 4.5 20.0 28.6
10 CHL 30.0 20.0 32.9 25.7 27.1 2.8 2.5 1.8 2.5 2.5 2.5 4.5 19.0 27.1
11 Plant S 26.4 26.4 2.0 1.4 2.5 4.0 2.6 4.0 2.0 18.5 26.4
12 Office 20.0 28.6 18.6 28.6 24.0 2.0 0.5 3.4 1.4 2.5 2.0 5.0 16.8 24.0
13 Plant Q 21.0 21.0 1.4 1.4 1.4 2.5 2.0 3.5 2.5 14.7 21.0
14 Plant R 18.6 18.6 1.5 1.6 1.4 2.5 2.0 2.0 2.0 13.0 18.6
15 Plant T 18.0 18.0 1.0 1.5 1.6 2.5 2.0 2.0 2.0 12.6 18.0
16 Heater 17.9 0.0 1.5 1.5 1.5 1.0 4.0 3.0 12.5 17.9
17 Toilets 17.1 0.0 1.5 1.5 1.0 1.0 4.0 3.0 12.0 17.1
18 Premises 14.3 21.4 14.3 17.1 16.8 1.3 0.5 0.3 2.0 2.0 3.5 2.3 11.8 16.8
19 Changing Room 16.4 0.0 1.0 2.0 1.0 1.0 3.0 3.5 11.5 16.4
20 Compound 18.6 11.4 14.3 11.4 13.9 1.0 1.0 0.5 0.5 2.0 2.8 2.0 9.8 13.9
21 Canteen 13.6 1.0 1.0 0.5 0.5 2.0 2.5 2.0 9.5 13.6
First Places 2 4 4 5
Second Places 1 5 2 5
Cobra Cheeta Smart Black Eagle
0.0 1.0 0.5 2.0
6S audit- Final Results Marking Sheet
Zbd Index
• Carry out the audits to verify the sustainability of 6S & other improvements coming from ADT & PDT teams.
My Job Role – As Executive DOS
6S Winners summary in 2012
Team Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec summary
1 2 3 4
COBRA 2 2 1 2 3 2 2 1 3 4 3 2 3 2 6 4 1
CHEETA 3 4 2 1 2 3 3 2 2 1 4 1 1 4 4 3 2
SMART 1 1 3 3 1 4 4 4 1 3 2 4 2 4 2 3 4
BLACK EAGLE 4 3 4 4 4 1 1 3 4 2 1 3 4 3 1 3 6
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