By Eliminating Waste GPS Depth Study NVA/VA- Report Out ...€¦ · 9. Final Target Progress and Results Report (electronic) – TL 10. Newspaper – STL 11. Workshop Summary –

1 ©1996-2013, John Black and Associates LLC

Licensed Materials – USA Copyright Laws Apply

Mod 18 – Report Out

18 Report Out v20140608

Global Production System

Product/Patient Quantity Analysis

Kaizen Kaikuku

Just-in-Time

Measures

Standard

Operations

Heijunka

(Leveling)

Continuous

Flow

Total

Productive

Maintenance

Poka-yoke (mistake

proofing)

Kanban

Setup Reduction

Changeover

Multi-process

Operations

Jidoka (human

automation)

GPS

MUDA MUDA

Visual

Control

Andon

TAKT TIME ONE PIECE FLOW PULL PRODUCTION

R

e

d

e

p

l

o

y

m

e

n

t

Committed Leaders

Profit =

Price - Cost

TAKT Time Map

Capacity Tables

Cost Reduction By Eliminating Waste

GPS Depth Study

NVA/VA-

Functions/Mgrs

Quality Cost Delivery

Morale Safety

Value Stream Mapping

5S • Sorting

• Simplifying

• Sweeping

• Standardizing

• Self Discipline

3P Prod Prep

7 Flows Medicine

7

Wastes

RPIW

7 Flows

Factory

4 No’s

© 1996-2013, John Black and Associates LLC

(modified from Hiroyuki Hirano, Productivity Press).

Report Out

Module 18


18 Report Out v20130530 ©1996-2013, John Black and Associates LLC

Licensed Materials – USA Copyright Laws Apply 2

Report Outs

There are two types of Report Outs:

Prep Week/RPIW Week

These are meetings that report daily progress (status). They

provide feedback, guidance, and support to the Team.

Final Report Out

The purpose of the Final Report Out is to present the actual

results obtained during the week.




Prep Week/RPIW Week Report Out

(Sponsor Meeting)

The purpose of this Report Out is to report daily progress

(status) and provide feedback, guidance, and support to

the Team Lead and Sub-team Lead.

Attendees: Team Lead, Sub-team Lead, Sponsor,

Process Owner, KPO, JBA Consultant. No other

attendees allowed.

Schedule of meetings:

RPIW Prep Week Report Out.

Week -3: Tuesday, Wednesday, Thursday.

Week -2: Tuesday, Thursday.

Week -1: Wednesday.

RPIW Week Report Out: Tuesday, Wednesday.




Prep Week/RPIW Week Report Out

(Sponsor Meeting)

Team Lead presents to Takt Time of 10 minutes and will

present the following information (order of information

shown determined by Team Lead):

1. Current and accurate target sheets.

2. Supporting data (standard work combination sheets, time

observations, standard work sheets, percent load charts, etc.) as

applicable.

3. What team did today and how daily actions support RPIW

targets.

4. Plan of action for tomorrow and how that supports RPIW targets.

5. Barriers and concerns.

Team Lead has 5 minutes of Q&A with sponsor and process owner.

See the sample daily status meeting example that follows.





Daily Status Meeting Example Presentation

Agenda

Presentation

Contents Comments

Project Form Workshop Date ___ Workshop Area / Project:______________________

RIP Team / Resources

Production Requirements / Takt Time

Calculation

Process Information (Part

/Information Flow)

Current Situation

RIP Targets / Objectives

/Boundaries

• Describe any

changes in current

situation.

• Relevant PQA.

• Other background

information.

RPIW Target

Sheet

• Highlight starting

point for key

measures.

• Discuss target for

each measure.

• Discuss progress to

date.

Target Progress Report and Results Sheet

Team Name: Date: Department: TAKT Time: Product/Process: Team Leader:

Measures Baseline Target Day 1 Day 2 Day 3 Final PercentChange

Space (Sq. Ft.)

Inventory

Walking Distance

Parts Travel Distance

Leadtime

Quality (# Defects)

Productivity Gain(# People)

Environmental, Health &Safety (5S)

Set-Up

Cycle Time

Remarks:

Takt Time Sheets # Shifts/Day (X) # of Hours/Shift (=) # of Hours/Day (X) 60 Minutes/Hours 60 (=) # of Minutes/Day ( - ) Breaks (Minutes) ( - ) Wash Time (Minutes) ( - ) Tool Change (Minutes) (=) Total Minutes Available/Day ( / ) Units Sales/Day

TAKT TIME: (=) Minutes per Unit _______ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _

OR: (X) 60 Seconds/Minute

TAKT TIME: (=) Seconds per Unit _______

• Takt Time sheet

required to support

the target sheet.





Presentation

Agenda

Presentation

Contents Comments

Q u a lityC h ec k

Sa f e tyPr e ca u t io n

St a n da r d W o r kIn - Pr o ce s s

# o f p ie ce s o f st dw o rk in - p ro c e ss

T a ktT im e

O p e ra t orN u m b er

Standard Work Shee tPr o ce s s Na m e:

M o d e l N u m b e r:

M o d e l N a m e :

Sc o p e o f

O p e ra t io ns

F r o m :

T o :

D a te :

D e pt . He a d Su p e r vis o r

M in i S aw - P un c h

x x 3 0

S c is s o r L if t

P un c h

W a s h

D E B U R

PU N C H

S A W 1

S A W 2

NO

T C HW

A S H

1

2

3

4

5

6

7

89

( BIG

BA

TCH

S)

3

Standard Work

Sheets

• People and

material flow.

• Show distance

traveled and time

• Both should be

clearly designated.

Time

Observations

Standard Work

Combination

Sheets

Process

Observation Time Observer Observation Date:

Step #

Description of Operation 1 2 3 4 5 6 7 8 9 10 11 12 Shortest Task Time

Remarks

Time for 1 Cycle

Standard Work Combination Sheet

Area: Operator No. or Name: Prepared By:

Date Prepared:

Process: No. Required per Day/Shift Manual: x - - - - - - - - - - - - - - -

Automatic: x . . . . . . . . . . . . .

Item Name: TAKT Time Required: Waiting: x = = = = = = = = = = = = = =

Current: Walking: x ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~

Step Time Operation Time (Seconds/Minutes)

No. Work Description M an. Auto Walk 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90

Totals

Waiting

• Show at least

one example.

• Show at least

one example.





Presentation

Agenda Presentation Contents Comments

Newspaper • Briefly go over things

that you are working on.

• Discuss what you will try

tomorrow and what you

think you will gain.

• Use this to show progress.

Barriers and plan

for tomorrow

RPIW Event #: Date: Team Name: Team Number:

Item # Problem Actions Needed toComplete

Responsibility Due Date Status% Complete

25% 50%

100% 75%

25% 50%

100% 75%

25% 50%

100% 75%

25% 50%

100% 75%

25% 50%

100% 75%

25% 50%

100% 75%

25% 50%

100% 75%

Newspaper Action Items

• Show cycle times

and number of

operators needed

Percent Load

Charts

Percent Load Chart (Ba r Chart)Process Name:

Product Line:

Model Name or Part:

Scope of

Operations

From:

To:

Date:

Department Supervisor

Tim

e

Operator

OperatorCycle Time

Sum Total of Operator

Cycle Times:Takt Time: SSum of Operator Cycle Times

Takt Time

O.C.T.

T.T.= = Team Members Required

Percent Load Chart .ppt

t/t = 630 sec

Sample

Lifting Stuff

GXV-2000

630 sec

540 sec 660 sec 490 sec 400 sec 540 sec

2630 sec 4.2

A B C D E

Idea Summary

Sheets

Employee/Area Problems Measures Taken Results

Before Improvement After Improvement

Remarks: Note:

• Show all ideas that

were generated

• Obtain feedback and

direction from sponsor,

process owner and JBA

Consultant.




Final Report Out The purpose of the Final Report Out is to present the actual

results obtained during the week.

Takt Time for the final report is 20 minutes per team.

Must have all required tools as per the RPIW Process Module and in the

appropriate order (shown on next slide).

ALL team members participate – NO EXCEPTIONS.

Pre and Post Kaizen video will run in the background of the presentation without

sound.

There will not be any questions at report out.

Team Lead flips slides for all team participants. Sub-team Lead will flip slides for

when Team Lead is presenting.

KPO Support does not participate in the report out but ensures video is running.

KPO Support will make a copy of the presentation for the Team Lead to hand off

to the Sponsor at the conclusion of the presentation.

Rehearse your presentation before Report Out to make sure you meet Takt Time.

See an example of an actual report out at the end of the module.





Final Report Out These tools will be completed in black sharpie with all RPIWs (no exceptions), in the

following order on numbered pages (bulleted items can go in any order between PQA Data

and the Newspaper):

1. Starting SWCS - TL

2. Team Picture - TL

3. Project Form (electronic) - TL

4. Baseline Target Progress and Results Report (electronic) - TL

5. Current State Value Stream Map - STL

6. Takt Time Form - STL

7. PQA Data – STL

8. Participants tell their story using a mix of the following: forms:

• Pre- and Post-Time Observation Form

• Pre- and Post-Standard Work Combination Sheet

• Pre- and Post- Standard Work Sheet

• Pre- and Post-Percent Load Bar Chart

• Idea Summary Sheet (minimum of 5)

• Standard Work/Work Standards

• Pre- and Post-5S Scores with pictures

9. Final Target Progress and Results Report (electronic) – TL

10. Newspaper – STL

11. Workshop Summary – TL or Participant

12. Thank you list – TL or Participant

20 minute video showing 10 minutes pre-kaizen and 10 minutes post-kaizen work

The JBA consultant will

ensure all forms are

completed with the

appropriate data and sign off

on all pages. No changes will

be made to the layout or set

up of the forms.

Support groups such as IT,

Facilities, Engineering,

Housekeeping, etc. will be

“on-call” for the RPIW.

The expectation is they will be

available any time the team

lead requests their support.

There should be a point person

from these groups identified for

the team lead.





Example: RPIW Report Out





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Documents

By Eliminating Waste GPS Depth Study NVA/VA- Report Out ...€¦ · 9. Final Target Progress and Results Report (electronic) – TL 10. Newspaper – STL 11. Workshop Summary –