© 2011 | Seite 1 Sustainable training of Office TPM using a “Teaching Office” Presentation at the 11th TPM National Conference 6-7 September 2011: Hotel Le Meridien, Chennai Prof. Dr. Constantin May Christoph Schaller
Dec 16, 2015
2011 | Seite 1
Sustainable training of Office TPM using a Teaching Office
Presentation at the11th TPM National Conference
6-7 September 2011: Hotel Le Meridien, Chennai
Prof. Dr. Constantin MayChristoph Schaller
2011 | Seite 2
Some facts on the CETPM
Founded in 2005 as a Institute of Ansbach University
Today the Leading Institution for TPM and Lean Management in German speaking Countries
Covers an Online-Community with more than 2500 Members
Offers Training and Study Courses in the field of TPM and Lean Management with an innovative didactical approachcalled Effective Learning
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Die Lehrfabrik Das Lehrbro The Learning FactoryThe Learning Office
Tell me and I will forget,Show me and I will remember, Let me do and I will understandLao Tse
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What is the learning factory?
The learning factory is an innovative centre for training and continuing education.
We use actual machinery in the learning factory, which enables the participants to identify with the work environment
The participants can apply their new knowledge immediately to practice
Currently we focus on training Lean Production in the Learning Factory but will start soon to use it for TPM training as well
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Authentic Factory Setting
TeachingTeaching FacilityFacility in a in a formerformer garmentgarment factoryfactory
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Shopfloor overview beforebefore
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Shopfloor overview afterafter weekweek 11
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Shopfloor overview afterafter weekweek 22
See the transformation at http://www.cetpm.de/video.21.html
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What is the Learning Office?
Just as the learning factory concentrates on manufacturing, the learning office shows how to improve administrative processes
The Learning Office realizes an order management process with all relevant steps, from taking a customer order to processing the order and issuing the invoice.
All theoretical learning content can be applied immediately to fight the 16 losses in administration.
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The CETPM Approach: 6 Level for Office TPM
Level 1Create proper
starting position
by
Level 2Optimization of
Level 3Savings by
Level 4Improve reached
Level by further
Level 5Full responsibility by
Level 6Controlled
Processes by
Self-
organization
Awareness of 16 Losses 5S Campaign Targets and Roadmap
Cooperation
Standards for Processes Standards (Folder System) I&C-Standards Kanban for Office Material Service-Standards
Process-
improvement
Optimized
Teamwork
Visual Management Team Boards Structured Targets
Flexible Work
in Teams
Analysis of Tasks Concept for Mobility Room- and l&C-Concept
Best in class 0-Losses Benchmarking
Awareness of Losses and
Starting of Loss-Elimination
0-Defects
0-Throughput Time
0-Paper
100% Visual Management
and structured targets
100% Flexibility
0-Space
Zero Losses
Makigami Structured
Problemsolving
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Training schedule in the Learning Office
week 1
week 2
week 4
week 1
week 3
3 days training
Implementation at
participants company
3 days training
Implementation at
participants company
3 days training
Fundamentals of Office TPM5S Method, Improvement within teamsTeambuilding
Project: 5S-implementationProject: Implementation of a Standard
Process Improvement with Makigami
Project: Process Improvement with Makigami
Change Management / Leadership of ChangeKPIs for Office TPMPresentation of the participants projects
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Makigami means Roll of Paper
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How to create a Makigami
Department 4
Department 1
Department 2
Department 3
Which process ?Which process ?
1 2 3 4
Step 1
Step 2
Step 3
Step 4
forms
data
medium
forms
data
medium
forms
data
medium
1
1
1
07:00 am Day 2 07:00 am 07:10 am 07:30 am
30 min 10 min 20 min 10 min
5 min 2 min0 min 0 min
25 min 10 min 20 min 8 min
3
1480 min
70 min
7 min
63 min
0,54 %
= non-value adding
= value adding% value creation = total of value adding time / total time * 100
Process:
Individual or department /
action
Data m
edium
total time:
total action:
total value
adding:
Date
Action time
Value adding
Losses
Data and
information medium
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Makigami Step by Step
Description of the process
Determine the individuals or departments, that have to
deal with the process
Work out every single stage in the process with the
group. Determine the data medium and attach it.
Connect all stages of the process with red or green
arrows.
Red = Defects may arise or information is missing.
Green = There are no defects and all information is
available.
Analyze each stage of the process if it is value adding
or not. Examination with the following criteria:
1. Is the process improved?
2. Is the customer pleased with it?
3. Are there any statutory regulations?
Add the timeline
Please note: also include the weekend, time after the
end of work etc.
Elaborate the action times (the time in which an action
really takes place).
Elaborate the value adding time. Find your way through all
the items again by asking how much value adding time is
really included.
Calculate the lost time: action time value adding time
Count the transfers. A transfer comes up when information
is being passed on to a person/department.
Determine the number of all data mediums.
Determine the total time.
If the problem can be determined through analyzing the process, please make a note on a red post-it and fix it underneath the
corresponding stage.
Suggestion for coloring the notes (post-its):
yellow = stage of the process
red = problems
green = suggestion for improvement (as an idea repository)
Suggestion for team formation (max 5-6 people):
2-3 employees who know the process
2-3 employees who dont know the process (are important,
because these employees ask the so-called silly questions).
A responsible instructor to lead the analysis.
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Order Management Process
salescustomer
productionshippingbilling
order processing
scheduling
places orders takes orders and sends confirmation
creates internalconfirmation and production order
providescomponents
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salescustomer
productionshippingbilling
order processing
scheduling
creats bill creates shipping
documents and packsclipboard
assemblesclipboard
Order Management Process
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I order my clipboard at the training company
Clipboard Ltd.
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I am the voice to thecustomer and take his
orders
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I check the technicalfeasibility
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I create theproduction order
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I schedule all components for
production
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I assemble theclipboard
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I pack the clipboardand create the
shipping documents
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I create the invoice
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Impressions
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Impressions
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Impressions
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Example Result from the Learning Office before
Logistic
Shipping
Scheduling
Employee 2
Sales
Customer
Billing
Employee 1
Production
Training room
Office 2
Office 1
Production
Post Office
Information
Material
Flow of Material and Information
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Example Result from the Learning Office after
Logistic
Shipping
Scheduling Employee 1+2 Sales
Customer
Billing
Production
Training room
Office 2Post Office
Production
Information
Material
Flow of Material and Information
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Thank you for your attention!
Please do not hesitate to contact us for further information.