founded in 1947 by mr. joseph fleischhacker with an investment of $400. primary focus was to...
TRANSCRIPT
Founded in 1947 by Mr. Joseph Fleischhacker with an investment of $400.
Primary focus was to manufacture fishing lures & tackle.
Original manufacturing location was a renovated chicken coop behind the Fleischhacker family home.
Approached by Medtronic to develop a small diameter pacing lead coil which led to the move into the medical device industry.
Company History
Remains a family owned OEM company.
Headquarters in Chaska, Minnesota, USA.
Manufacturing facility in New Ross, Ireland.
International Research & Development Centre in Galway, Ireland.
Sales Office & Stocking Warehouse in Shanghai, China.
Company Profile
Continuous Improvement IS NOT….
About turning the company into a sweat shop
Cutting corners to reduce cost
Compromising quality to increase efficiency
What is C.I. / Lean?
Continuous Improvement IS…
All employees applying themselves fully to the task at hand About striving every day to improve your work Finding the one best way to carry out a job and standardising it C.I. requires involvement from everyone in the company It is about making more with less
Reducing costs Improving quality Preventing and eliminating waste
Lean manufacturing provides us with the philosophy and methods to achieve this…
What is C.I. / Lean?
BACKGROUND TO SHINGO
Named after Japanese industrial engineer; Dr. Shigeo Shingo
The Prize was established in 1988 to promote awareness of Lean manufacturing concepts and recognise companies that achieve world-class status
Described as the “Nobel Prize for Manufacturing” by Business Week
Universal, timeless & self-evident
SHINGO RECOGNITION LEVELS
AWARD SCORE
The Shingo Prize 775 +
Silver Medallion 675 – 774
Bronze Medallion 575 – 674
SHINGO - MORE THAN JUST A PRIZE
World renowned accreditation – would greatly benefit our marketing strategy
External recognition of operational excellence
Provides a road map for endless continuous improvement journey
Highlights our strengths and opportunities for improvement
LRM SHINGO JOURNEY
Jan 2010: Steering Group
June 2010: Shingo Workshop in Covidien
Aug 2010: 1st Gap Analysis Audit by The Mfg Ins.
Nov 2011: 2nd Gap Analysis Audit by The Mfg Ins.
Nov 2011: Submit Results Section
Jan 2012:Submit Achievement Report
Apr 2012: Began prepping employees for audit
May 2012: Official Shingo Audit
Submit Results Section Nov 2011
Dimension 4 – Results: Describe your organizations philosophy towards creating value as it relates to the principles outlined in the Shingo model (2 pages)Provide >3 years data under the following headings:
Quality (2 Pages)
Cost / Productivity (2 Pages)
Delivery (2 Pages)
Customer Satisfaction (2 Pages)
Morale (2 Pages)
Submit Achievement Report Jan 2012
The A.R. (45 Pages) details how the applying organization has transformed its culture using Shingo principles of Op Ex.
Dimension 1 – Cultural Enablers: Describe how your organization drive principle based behaviour in each subsection. Clearly discuss use of tools & systems.
Dimension 2 – Continuous Process Improvement: Describe your organizations philosophy towards applying lean principles and concepts.
Dimension 3 – Enterprise Alignment: Describe organizations lean culture and clearly discuss examples of tools, systems & principles in each business process.
Areas of clarification (Achievement Report) 8th May
• Question 45: Explain the goal to reduce inventory and the benefits you expect to receive. Show the aggregated inventory figures broken down into categories over 2011 (by week) i.e. purchased parts, internally manufactured components, work in progress, raw material, finished parts inventory, consignment stock. Explain how the inventory measure is relevant to this business and how it is directly linked to customer satisfaction. How is the inventory level calculated and linked to principles of the model? Clarify how the two inventory measures work together.
• Question 60: Please demonstrate, through use of data, how you systematically identify and eliminate the causes of scrap on your lines
• Question 72: Page 37 shows an hourly target vs hourly actual measurement. Please explain how the target is calculated, and for what purpose is it used. Additionally do you pay attention to the target vs actual variance? If so what is the data used for? Also, further explanation and clarification is needed for the line side measure.
AGENDA – DAY 1 (MORNING) Wednesday 23rd May 2012
1 2 3 4 5 Location Activity
06:50 06:55 Reception Assessors arrive on s ite, issue vis itor badges, etc.
06:55 07:05 Large Boardroom Introductions - m eet Director Group
07:05 08:00 Large Boardroom Overview presentation
08:00 11:00 Start at Shipping Go-look-see s ite walk & observation (reverse flow)
11:00 12:00 Large Boardroom Lunch
12:00 12:30 Large Boardroom Exam iner Caucus
HV Precoat cell #1 Meet with group of front-line s taff - HV Precoat
Speciality Meet with group of front-line s taff - CCA
CI Room Meet with group of Operations Supervisors
Maint. Area (HV) Meet with group of Technicians
Warehouse (BII) Meet with group of front-line s taff
Tony's Office Meet with Finance / IT Director
IT Office Meet with IT Group
Renee's Office Meet with HR & Training Group
CI Room Weekly PMR Meeting - Week 4
Maint. Area (HV) Meet with Maintenance Senior Group
Eddie's Office Meet with Operations Director
Seam us ' Office Meet with Planning Group
Sm all Boardroom Meet with Procurem ent Group
Eoin's Office Meet with Operations Senior Supervisors
Large Boardroom Afternoon refreshm ents
Sm all Boardroom Meet with Quality Director
Margaret's Office Meet with Quality Senior Group
CI Room Meet with Continuous Im provem ent Group
Barry's Office
Large Boardroom Meet with group of Engineers
Cust.Service Office Meet with Custom er Service Group
Rois in's Office Meet with EHS Group
Donal's Office Meet with Facilities Group
LV Odds & Sods Meet with group of front-line s taff
Packaging Meet with group of front-line s taff
Bulk Packaging Meet with group of front-line s taff
Shipping Meet with group of front-line s taff
Des ign Office / BII Meet with Autom ation Des ign Group
CI Room Meet with group of Trainers
Toolroom Meet with Toolroom Group
17:00 17:30 Large Boardroom Modify day 2 schedule
Depart
14:45
ExaminersDAY 1
Time
12:30 13:15
14:00
13:15 14:00
AGENDA – DAY 1 (AFTERNOON)
Wednesday 23rd May 2012
1 2 3 4 5 Location Activity
06:50 06:55 Reception Assessors arrive on s ite, issue vis itor badges , etc.
06:55 07:05 Large Boardroom Introductions - m eet Director Group
07:05 08:00 Large Boardroom Overview presentation
08:00 11:00 Start at Shipping Go-look-see s ite walk & observation (reverse flow)
11:00 12:00 Large Boardroom Lunch
12:00 12:30 Large Boardroom Exam iner Caucus
HV Precoat cell #1 Meet with group of front-line s taff - HV Precoat
Speciality Meet with group of front-line s taff - CCA
CI Room Meet with group of Operations Supervisors
Maint. Area (HV) Meet with group of Technicians
Warehouse (BII) Meet with group of front-line s taff
Tony's Office Meet with Finance / IT Director
IT Office Meet with IT Group
Renee's Office Meet with HR & Training Group
CI Room
Maint. Area (HV) Meet with Maintenance Senior Group
Eddie's Office Meet with Operations Director
Seam us ' Office
Sm all Boardroom Meet with Procurem ent Group
Eoin's Office Meet with Operations Senior Supervisors
Large Boardroom Afternoon refreshm ents
Sm all Boardroom Meet with Quality Director
Margaret's Office Meet with Quality Senior Group
CI Room Meet with Continuous Im provem ent Group
Barry's Office Meet with Engineering Senior Group
Large Boardroom Meet with group of Engineers
Cust.Service Office Meet with Cus tom er Service Group
Rois in's Office Meet with EHS Group
Donal's Office Meet with Facilities Group
LV Odds & Sods Meet with group of front-line s taff
Packaging Meet with group of front-line s taff
Bulk Packaging Meet with group of front-line s taff
Shipping Meet with group of front-line s taff
Des ign Office / BII Meet with Autom ation Des ign Group
CI Room Meet with group of Trainers
Toolroom Meet with Toolroom Group
17:00 17:30 Large Boardroom Modify day 2 schedule
Depart
14:45
14:45 15:30
14:45
15:30
14:00
16:15
16:15 17:00
17:30
Wednesday 23rd May 2012
1 2 3 4 5 Location Activity
06:50 06:55 Reception Assessors arrive on s ite, issue vis itor badges, etc.
06:55 07:05 Large Boardroom Introductions - m eet Director Group
07:05 08:00 Large Boardroom Overview presentation
08:00 11:00 Start at Shipping Go-look-see s ite walk & observation (reverse flow)
11:00 12:00 Large Boardroom Lunch
12:00 12:30 Large Boardroom Exam iner Caucus
HV Precoat cell #1 Meet with group of front-line s taff - HV Precoat
Speciality Meet with group of front-line s taff - CCA
CI Room Meet with group of Operations Supervisors
Maint. Area (HV) Meet with group of Technicians
Warehouse (BII) Meet with group of front-line s taff
Tony's Office Meet with Finance / IT Director
IT Office Meet with IT Group
Renee's Office Meet with HR & Training Group
CI Room
Maint. Area (HV) Meet with Maintenance Senior Group
Eddie's Office Meet with Operations Director
Seam us ' Office
Sm all Boardroom Meet with Procurem ent Group
Eoin's Office Meet with Operations Senior Supervisors
Large Boardroom Afternoon refreshm ents
Sm all Boardroom Meet with Quality Director
Margaret's Office Meet with Quality Senior Group
CI Room Meet with Continuous Im provem ent Group
Barry's Office
Large Boardroom Meet with group of Engineers
Cust.Service Office Meet with Custom er Service Group
Rois in's Office Meet with EHS Group
Donal's Office Meet with Facilities Group
LV Odds & Sods Meet with group of front-line s taff
Packaging Meet with group of front-line s taff
Bulk Packaging Meet with group of front-line s taff
Shipping Meet with group of front-line s taff
Des ign Office / BII Meet with Autom ation Des ign Group
CI Room Meet with group of Trainers
Toolroom Meet with Toolroom Group
17:00 17:30 Large Boardroom Modify day 2 schedule
Depart
ExaminersDAY 1
Time
What wastes have you eliminated / reduced?
How are you adding value?
Is your opinion valued?
How have you improved your work? – Who was involved?
Why have you done this?
Who are your customers?
Flow
What are your KPI’s
How often do you see directors on the factory floor?
Do you like coming to work at Lake Region ?
SHINGO AUDIT QUESTIONS
ANY QUESTIONS?