What I did at DPL -Print 1

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

1st Operation Planning Meeting – January 2010

Joint Operation Centre ( JOC) – Place for Operation

1st Operation Excellence Review Function – Feb. 2010

1st Operation Excellence Review Function – Feb. 2010

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

3 Lean Training programs, 20 Lean Teams, 200 Educated Employees about Lean Tools

Operation Planning Meeting (OPM)

ROR – Real time Operation Review

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

Sharing Experience taken from monthly Operation

Monthly Operation Excellence Review

Awarding the Winners of the monthly Operation

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

• OEE increase from 64% to 86.5% from January 2010

to February 2013.

Achievements

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

• Prepare & update cost savings coming from DOS activities to communicate to the relevant parties.

My Job Role – As Executive DOS