leader standard work: shopfloor management2018/09/11 · our shopfloor management system is known...

Leader Standard Work: Shopfloor Management

Continental Automotive Hungary Kft.

InternalSpace for Sender Information

Agenda

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1 What is LSW: Shopfloor Management?

2 How does LSW look at the shopfloor?

3 How is LSW measured?


Agenda

11 September 20183


How is LSW measured?

JL Ordorica © Continental AG

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How does LSW look at the shopfloor?2


› Lean Management System: Daily Management System that ensures that standardsare followed, continuous improvement is done everyday and ensures that employees develop a lean mindset .

› A Lean Management System at the shopfloor is known as Shopfloor Management System. Our shopfloor management system is known as:

Leader Standard Work: Shopfloor Management.

› Lean Production System: Collection of methods and tools to make any process lean. In Continental it is covered in Continental Business System (CBS).

What is LSW: Shopfloor Management?Definition

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What is LSW: Shopfloor Management?

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Tools / Method focus(Island mode)

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Target

Without LSW

New Problem New Problem

Old Problems

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With LSW

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Target

With LSW + PS

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SW

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S

What is LSW: Shopfloor Management?LSW: Shopfloor Management with systematic approach


› Focusing on “whatever it takes”

Results are negative during the most part of the month but suddenly appear at the end of the month

› Focusing on Process

“Process delivers the result by building up duringthe month“Result is predictable

What is LSW: Shopfloor Management?Why Leader Standard Work?

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Traditional LSW

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Target Target

“Heroics“?

LSW routines must be focused in “Preventive“

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Agenda

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InternalSpace for Sender InformationSpace for Sender Information 11 September 2018

9JL Ordorica © Continental AG

Employee development:

Coaching/Lean Dialogues

Standardized Meetings

Standardized Gemba Walks

Systematic Problem Solving

LSW

Process visualization at the Line &

Deviation Management

Routines to sustain standards

Elements of LSW


› Meetings are standardized through the location. So everybody respects those Meetings (inclusive Agenda + location)

› Can be used in Admin and shoplfloor area too

› Ensures information and escalation flow

› Everybody is prepeared based on the standard agenda and participationlist

› Dedicated time for daily routines

How does LSW look at the shopfloor?Standardized Meetings

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11Author, © Continental AG

› Fast problem solving

› Dedicated time forengineers (A3, PDCA, OIL)

› Daily production line meeting

› Daily production cluster meeting

› Golooksee (JIT PS)

› Daily production leader meeting

Daily structure

Downtime discussion Weekly LPA Scrap discussion Weekly 5S

A3 review / production area Management + 2nd level A3 review / production area Management + 2nd level

Weekly structure


How does LSW look at the shopfloor?Standardized Meetings & Gemba walk

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What it is not What it is

› Random Meeting

› No Standard Agenda

› Participation not fixed

› Random Walk - Risk of “witch hunt”

› Fixed Meeting Schedule

› Standard Agenda

› Standard Participation

› Everybody is prepared and knows the expectations for the meeting

› Everybody is prepared and knows the expectations for the Gemba Walk





Elements of LSW





LSW

Space for Sender Information





How does LSW look at the shopfloor?Process visualization at the Line

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Main Working Tool for Line Leader and forManagement to follow up the area



How does LSW look at the shopfloor?Deviation Management

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Deviations comefrom 2 sources:› KPI‘s (Target)› Standards –

Deviations (e.g. SW, 5S, Jidoka,…)



› Electronic or manual Information that does not drive actions

› Issues are captured but accountability is not clear or not fixed on time

How does LSW look at the shopfloor?Process visualization at the Line

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› Visualization should reflect current and target condition of the process

› Drive action by Line Leader, support functions and Management

› Deviation Management is transparent:

› Deviations are captured

› Issues fixed on time

› Clear accountability





Elements of LSW





LSW






Obeya room

› When does the area execute Problem Solving (PS)?

› Example:

How does LSW look at the shopfloor?Systematic Problem Solving

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Issue� Fixed

with action

Action list:Reocurrence

Sent to„Kaizen

Corner“ todo PS

Selects top Problems of areas

supported___________________________________________________________________________

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Feedback Line through Line Leader

Support team does PS

EngineerQAMaintenanceLine Leader…

Line Leader Follow up Kaizen Corner

Yes

Trigger: PS





Elements of LSW





LSW






How does LSW look at the shopfloor?Routines to sustain standards

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PATH

Plant Manager

FF Manager

Production Manager

Shift Manager

Line Leader


Microsoft Excel

Worksheet

Standard work

confirmation Line output5S

Cycle timeconfirmation

JidokaNon-

conformanceMgt.

Poka Yoke

Problemsolving

ESD complience

Shift start up process

MaintenancePerformance overwie (KPI)


› Routines are the „Job description“

› A routine is not a random audit

How does LSW look at the shopfloor?Routines to sustain standards

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› Routines assure that the Standards are complied on a day to day

› Routines can be improved like any other Standard

› Mandatory Routines and routines defined by plants complement each other





Elements of LSW





LSW






› General talks about new tools or methods that may not even apply or the area may not be ready

› Telling people what they should do (Solutions)

How does LSW look at the shopfloor?Employee development: Coaching / Lean Dialogues

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› Coaching the employee so he/she can develop its own solutions on the topics that are priority or the biggest hurdles



Agenda

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Expected benefits


Quantifiable

› Score card improvement (KPI)

› Cost savings

› Cost Avoidance

Soft

› Development of people

› Improvement on ideas



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leader standard work: shopfloor management2018/09/11 · our shopfloor management system is known...

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