keep your 3-legged stool upright! leading successful manufacturing projects
TRANSCRIPT
Keep Your 3-Legged Stool Upright!
Successful Project Management
Brian HarringtonMTN-SIM, LLC
SIMUL8 Corporation | SIMUL8.com | [email protected]
About the Presenter
Brian Harrington is a Six Sigma Black Belt with 20 years operations research and simulation experience at Ford Motor Company. He designs and implements manufacturing process improvements which incorporate many conflicting objectives such as robust, flexible, and Lean systems.
Now running his own discrete event simulation specialists firm MTN-SIM LLC, he continues to deliver high quality complex models for a wide range of manufacturing, healthcare, and business process improvements. He also acts as a technical ambassador for SIMUL8 Corporation assisting in teaching, mentoring, marketing, and consulting projects.
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Housekeeping
1. Audio
2. Q and A
Recording available on: www.simul8.com
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Project Management using Simulation
• The facts• Factors to consider when managing a project
• Tools to identify key input factors
• Decision making using simulation• Creating trade-offs and balancing
MoneyTi
me
Quality
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The Facts…IBM Institute for Business Value Study
(48 countries, 1400 samples)
60% of projects fail to meet their objective44% fall short on at least one of their Cost, Quality, Time objectives15% miss all of their objectives or are stopped by management20% Highly successful (“Change Architects”)35% Moderately successful45% Below average successful
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1 Article: “Making Change Work” IBM 2010 Sample size 1,500 practitioners worldwide
2 Article: “Making change work . . . while the work keeps changing” IBM 2014Sample size 1,380 practitioners worldwideBy Hans-Henrik Jorgensen, Oliver Bruehl and Neele Franke 2014
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Cost, Quality, and TimeSmall or Large, Projects…
Need to be on Budget!On Time!
And Strive for Continuous Improve of Quality!
Project Management
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Conflicting Objectives
Sounds good to upper management, but how is this even possible?
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Enterprise Success Equates to…
Shorter Development Time Beating your Competition to Market
Delivering Quality
The pressure is on Project Management!
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Simulation- Reduces the Risk
Most successful companies use Discrete Event Simulation to address such critical factors as:
Cost, Quality, and Time
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What’s Critical
How do we know what to focus on when it comes Cost,
Quality, and Time?
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Critical to Quality, Cost, Time
Materials
Machinery/Equipment
Methods
People
Effect:Not achieving desired throughput
Companies need to focus on what is critical to the business and its customers.
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CT is Input into a QFDQuality Functional Deployment
• User Requirements into Design Parameters
• Correlation Matrix of the “What’s” & “How’s”
• Prioritizing what is most important
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Include C,Q,T Metrics into your Simulation
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Simulation metrics
• Throughput (JPH)– Changeovers– Batch Builds
• Number of Repairs– Repair rate
• Number of Scrapped Units– Scrap rate
• Cost– Number of Carriers– Number of Pallets– Number of Tugs & Racks– Number of Robots
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Finance & Income Statement
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Poll Question
Does your company’s managers use simulation results when comparing costly proposals?
A.Always (100%)B.Most of the time (80%)C.Some of the time (50%)D.Never
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SIMUL8 Corporation | SIMUL8.com | [email protected]
Cost
Cost Avoidance- Biggest bang for your buck!• Comparing simulation scenarios
Replication • Can you replicate these actions elsewhere?
Additional Cost Measures•Cost per unit•Material Costs•Scrap Costs
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Comparing Proposed SolutionsAutomated Guided Vehicle System
vs. Tugs and Racks
Large difference in cost per system.
What are the benefits of each system?
Will the company achieve these benefits?
Is there a better place to spend the funds?
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Quality
• Equipment
• Product Design
• Method/Process
• Tests• Repairs
Where to place quality equipment within your facility, and how much is necessary?
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Quality Example
Strategically placing a vision detection system to analysis weld integrity and
random imperfections.
Reduces scrapReduces destructive testing
Reduces heavy & light repairs
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Quality within a Bodyshop
Where to place quality equipment within your facility, and how much is necessary?
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Time
What Discrete Event Simulation does bestThe model is an animated database of events taking place at discrete times; producing realistic behavior and results.
Predicts the facilities capability (Parts per Hour) Provides insight into system performance (Wait, Blocked)
Optimize operating patterns (Shifts, Planned DT)Predicts long-term behavior (1 yr. of production)
Includes outliers (Catastrophic delays)
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We have the Time
Cycle TimesChangeover TimeBreakdown TimeShift PatternsConveyor SpeedsResource TimesTravel MatrixDwell TimesShelve Life TimeDelaysConditional TimeLoad TimeUnload TimeSimulation TimeWarm-up Time… The list goes on
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Overall Program Timing
As for project management the simulation analysis will reduce the overall development
time, it will keep the focus on the critical steps. Allowing managers to make decisions, accept implementation bids, and keep the program
moving forward.
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It’s a Bit of a Juggling Act
“Project management is like juggling three balls – time, cost and quality. Program management is
like a troupe of circus performers standing in a circle, each juggling-three balls and swapping balls
from time to time.”
– G. Reiss
1 Project Management Demystified: Today's Tools and Techniques GEOFF REISS
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Poll Question
How would you rate your company’s success with respect to Projects?
A.Highly SuccessfulB.Moderately SuccessfulC.Below Average
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SIMUL8 Corporation | SIMUL8.com | [email protected]
Balanced Project Management
Project Managers must keep the project moving forward
On TimeWithin BudgetBest in Class Quality
How?
Corporate Strategy
1.Data-backed Decisions
2.“Simulation Milestones” within your strategic timeline
3.“Simulation Sign-Offs”
Simulation studies must be sized properly to deliver Results at Key
Milestones!
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Keep your eye on the ballSimulation models can…
Address all three areas of concern
Justify trade-offs within your development plan
Identify interrelationships between key input factors
Provide the muscle to keep your project on target!
Q TC
Q TC
QTC
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Questions?
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SIMUL8 Corporation | SIMUL8.com | [email protected]
Questions?
If you have any questions around this topic, please email: [email protected]
Continue the discussion on the SIMUL8 Users Group– LinkedIn Group
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