shop floor management i
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1
The Mini-Company Concept
2
Mini-company concept
In business, president can run the organization successfully
and effectively.
More success will get more confidence from the investors.
If we view the next processes as the customer and the
previous processes as the supplier, every individual in the
organization can be president of his/ her area of
responsibilities.
This setting is called “mini-company”.
3
Steps in Running a Mini-Company
Name the mini-company
Write a mission statement for the mini-company
Make a company profile by listing people and machines etc
Develop customer-supplier relationship chart and discuss
meaning of the arrows
Clarify the objectives
Develop plans of action to achieve and then execute
Monitor the progress and celebrate accomplishment
Repeat this cycle regularly
4
Roles and Responsibilities of Supervisor
Working with top/ middle management
Developing the goals and approaches
Executing plans, checking the progress and reporting the results
Working with operators
Sharing of goals and utilizing operators’ ideas
Providing necessary education and training
Working with people from downstream (customers)
Understanding customers’ requirement clearly
Controlling the process to assure customers’ satisfaction
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Roles and Responsibilities of Supervisor
Working with people from upstream (suppliers)
Providing feedback
Receiving education and training to upgrade
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Meaning of Mission
Each mini-company have its own mission or value
statement.
If people have ownership in what they do, this statement
will help them work as team and share understanding.
So when we prepare mission statement, it should be
something that we can identify.
And if we think like that, whatever we do in organization
become expression of our mission statement.
To express this as : Organization Problems = Mission –
Current Situation
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Benefits of Mini-Companies
If we understand mission and if we try to live with the
mission in mind, our behavior should change
While implementing mini-company concept, every person
should be doing as part of his or her job responsibility
Sense of ownership
Work as a team
Focus on clear objectives
Barriers will be reduced
Cross-functional linkage
Identifying the areas of improvement
Participate
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Glass Wall Management
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Glass wall management
Running mini-companies in an isolated setting is not good
enough
Company needs to find ways to further tie people’s creative
resources together
Glass wall indicates open communication throughout the
company
Key characteristics of Glass Wall Management
It is consciousness-driven
Everything is aboveboard
Progress is shared
Free market system is practiced within company
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Comparison between Black Box and Glass Wall
Black Box Glass Wall
Top Management Word hard to manage Work hard to lead
Results oriented Results and process oriented
Short-term oriented Long-term oriented
Use people as machine View people as source of creativity
Middle Management Specialize in certain field Have boarder view
Do not share knowledge Share knowledge and experience
Do not help others Help others
Direct people to get things done
Lead, empower people to be done
Protect the current job Try to eliminate current job
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Comparison between Black Box and Glass Wall
Black Box Glass Wall
People at Shop Floor Not asked to use brain Encourage to use brain
No ownership Have ownership of what they do
Creativity is hidden Creativity is exposed
Small share of contribution Large share of contribution
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Customer-Oriented Organization
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Customer-Oriented Organization
Every businesses try to focus on satisfying their customers’
needs.
Whoever provide better services or products can compete with
the others.
Customer-supplier relationship is the closed loop.
Everybody who are participate in this relationship try to provide
better services or products continuously.
Everybody in the organization try to draw customer-supplier
relationship chart.
By doing like this, there are so many benefits which can be get.
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Customer-Oriented Organization
Developing the boarder view of the one’s job
Identifying the key customers
Clarifying roles and responsibilities
Clarifying the interrelationship in the organization
Educating new employees
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Local Optimization to Total Optimization
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Local Optimization to Total Optimization
As the customer-supplier relationship become clear, the
skills of employee who try to satisfy the customer’s needs
will be continuous improvement.
By providing the satisfy to the customers can lead the
organization to the better customer-oriented organization
If there are lack of information and lack of materials, the
organization will face the problems at the organization’s
boundaries and this can block the employees’ view and
ideas on the organization.
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Local Optimization to Total Optimization
Even there is the high lever of materials inventory or the
enough information, the organization can face the high
rejection rate.
This can be called as the local optimization.
On the other hand, if there are more communication and
cooperation, the organization can eliminate the problems at
the boundary level and more provide better customers’
satisfaction.
Moreover people can communicate across the organization
openly and freely, so the process can be done more smoothly.
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Standard Operating Procedures (SOP)
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Standard Operating Procedures
The purpose of SOP is for achieving the highest value-
adding work.
SOP aims for eliminating the wastes and eliminating the
over-burdens.
Key criteria's for SOP
Focus on operator’s movement
Apply for repetitive operation
Create on the shop floor
Developed by the operators
Improved or modified continuously
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Standard Operating Procedures
In order to practice SOP effectively,
Display in the working area, not keep under the desk
Comparing the prescribed work with the actual
Used for training the employees
Like as a mirror. If there is no improvement in SOP, there will be little
problems
Point out the real cause of the problems