Shop Floor Management

Shop Floor Management (SFM) helps the constant improvement of processes and procedures on the shop floor. The presence of mgmt. level staffing in manufacturing and their recognition on deviations from requirements dramatically hastens decision-making and consequences with inside the on the spot implementation of solutions.

Shop Floor Management really defines control duties and calls for unique modes of conduct. Management is supported via way of means of the utility of unique equipment. Five Shop Floor Management-associated duties are performed on the Shop Floor and are as follows:

1. Install regular communication

2. Confirm processes

3. Empower/Qualify staff

4. Make it part of the continuous improvement process (CIP)

5. Conduct problem solving in a structured approach

SFM emphasizes behavior that encourages your staff to resolve issues inside their scope of capabilities and strive for continuous improvement.

For example, management maintains its remarks to a minimum, handiest makes binding commitments, offers however additionally accepts feedback, profits its personal attitude of a situation, lets in errors in mastering situations, does now no longer lay blame and places in vicinity wondering techniques. SFM tools help the effectiveness of SFMgmt. e.g.:

• Production diary, KPI charts, hassle-fixing sheet, T-cards

• Shopfloor Management

• What is Shopfloor Management?

• Shopfloor Management

• Basic components of shop floor mgmt

• Clear management roles and responsibilities

• Regular communication (Gemba Walks)

• Key Performance Indicators

• Problem-solving techniques

• Visualization

Some explanation of the basics of operational leadership in shop floor mgmt. you organization will for sure profit from clear leadership roles and tasks. Your employees want near help for independent problem solving. Large control gaps, wherein the direct touch among the supervisor and his personnel and associates is reduced, normally do now no longer show themselves.

The Japanese version of a classical institution leader (Hancho), with a totally small management margin and occasional willpower of the personnel, regularly does now no longer suit into the qualified operator in organizations. The excessive qualification of operators is a vital aggressive thing in industry. In order to make suitable use of those capabilities with inside the processes, disciplinary management has the mission of the use of SMART´en to acquire desires at the same time as keeping room for manoeuvre and keeping a very good stability among needs and help.

Managers at the first mgmt. level do now no longer meet those demanding situations via time control seminars, however via greater practical duties and requirement profiles. Examine whether or not it's far important to introduce extra technical management as an alleviation for the first mgmt. level to your organization (CIP coordinator, Kaizen Manager, Process Champion). This feature can stand up from the present functions.

Jointly have a look at the opportunities of dispensing distinctive information regions (5S, set-up time reduction, CIP etc.) with inside the assembly teams expand collectively with you a brand new blending answer specially appropriate for you.

Regular communication

Regular communication is the structured approach to create a framework on a regular basis for opportunities. In this rhythm issues can be carried out and discussed across the management levels. Regular communication is an integral part of the day to day work of all players in your organization.

This way of communication, no matter if you call it huddles, stand up meetings, shop floor meetings, etc. guarantees a continuous flow of information without loss of information itself as it is fast and recurring. A subject matter-associated exchange takes place where employees are enabled to independently define measures, hassle answers and pointers for development and to remedy conflicts as quick as possible.

The continuous flow of information between the departments throughout the complete organization is guaranteed through these regular and short meetings. One positive side effect is that with regular communication you will also calm down daily operations management by clearly separating the topics (e.g. operative commercial enterprise, 5S, CIP, etc.). It is vital that these regular meetings are performed continuously and adhered to in order that normal communique will become independent.

Key Performance Indicators

Regular communication can only exist if the information inside these meetings are defined and standardized. The standard of these meetings is not only the agenda but more important the Key Performance Indicators (KPI). The target of working with KPIs is to have a framework for employees that provides information on the achievement of objectives. When you want to successfully control your production be aware that KPIs are broken down in such a way that they have a direct connection to the operators or designated workstation. Only then they are becoming a real instrument of control by which teams and departments can be measured. The positive thing about KPIs is that with the continuous improvement process paired with a structured problem solving approach all employees will see the effect of implemented measures on the KPIs. To get the full information on KPIs go here.

Problem Solving

Problem solving isn’t always as simple as it sounds, but it clearly shows the effectiveness of clear shop floor management. There are plenty of problem solving methods out there (Ishikawa, 5 Why, A3, Root Cause Analysis, just to name a few) and lean methods (e.g. 5S, set-up time reduction, Hejunka etc.) are well known in the manufacturing industry. But these methods are there to help your organization to deal with more complex issues, this means that they are not really useful for operators that are dealing with daily production but more for a problem solving team consisting of employees from different departments.

To tackle problem solving the right and sustainable way the role of a Kaizen Manager should be installed in your organization in order to steer the problem solving and continuous improvement process. Kaizen Manager help you to get out of this “fire fighting mode” with a sustainable CIP culture.

Visualization

For a clear visualization of running process in your organization, cleanliness and orderliness is the main part of it. Clarity of your processes on the shop floor is the foundation for all lean manufacturing activities. Having the clarity the implementation and maintaining of visual management methods will guide you to a real state of flow.

There are different ways for visualization out there (find a deeper insight here)

The target with visual management and those methods are all the same:

1. Create transparency

2. Visual representation of procedures processes and services

3. Making problems (or bottlenecks) visible

All documents and information are daily updated and right at the place of action clearly visualized for everybody in the organization (e.g. blackboards, Workflow Boards, Shop Floor Boards, Andon Boards, etc.).

Following the PDCA cycle the status of problem solving activities are recorded and visualized. KPIs on different topics are installed and tracked and so on. Important is only that all this information follows also a clear structure and has its own spot on the shop floor (e.g. a shop floor corner). Visualization starts at the workplace of a operator and ends at the management board of the plant manager or owner of the organization.

But in the end it always supports the Continuous Improvement Process in order to bring your organization the next level or simply to overachieve your customers expectations. To get a full insight in Visual Management, read the full article here.

Coaching

There is no denying that the abilities of a coachee to perform and learn are enhanced when they are encouraged by a coach to form solutions to the problems which they are confronting. This is exactly what coaching is. A coach may not be an expert, but for sure they can be regarded as the technical point of contact and are asked for their opinion and advice.

It has now become quite common to see supervisors coaching their employees. There can be a five steps procedure been seen in order to define and achieve goals.

At this point I want to recommend the book written by Anne Loehr and Brian Emerson, "A Manager’s Guide to Coaching" demonstrates how managers or supervisors can help their employees enhance their skills and develop themselves without the need for any additional training.

An employee’s success depends on “aptitude, attitude and resources.” Attitude matters most. In fact, a better outlook can make up for shortfalls in skills or materials.

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But let us go back to the five steps of the coaching process.

Step 1: Define the target state

In Step 1 we focus on defining the required outcomes. Get the clarity to define goals or future states. It is proven that those individuals who are clear regarding their goals are most likely to achieve them to those who have not defined their goals in a clear manner. Not having well-defined objectives can result in unpleasant side effects, for instance, preoccupying yourself with details. A successful and effective goal must be created by the coachee itself and must concur with their personal values. It is important to make certain goals a bit challenging, as easily achieving results cannot sometimes prove to be less motivating. On the flip side, it is also essential that some goals must have manageable and realistic partial steps so that, in general, it can be considered as achievable.

Step 2: Status Quo

The main aim in the second step is to identify the delta between the current state and the ideal solution within the structure of the current situation analysis. It is also important to assess the psychological and real cost that comes to light, especially when the client is clung to their current situation. Doing this can challenge the client to provide the energy required for the change. With that being said than just a small amount of time must be spent on assessing the Status Quo, and most of the focus must be given to achieving the desired outcomes. You should not expect any solutions at this particular stage.

Step 3: Costs of Opportunity

At this stage, the client needs to develop feelings for their own resources and their possibilities of gaining control of it: "When you feel resourceful, you feel in control, and when you feel in control, you feel confident." The feelings of control are mainly developed on the basis of the knowledge that there are different options and choices. The coach motivates the coachee to identify various options, by which the probability of determining between the non-action and action would already be recognized and appreciated. For the purpose of identifying different options, brainstorming has proven to be extremely helpful. It involves writing everything which crosses your mind regarding the particular subject in a creative and playful manner without evaluating them. The next step involves coachees opting for the options that look more beneficial and effective. These options are then assessed, and their consequences are analyzed concerning various criteria. Because one thing is certain – every option comes at some cost. Make sure that the coachee is willing to pay it.

Step 4: Taking Action

It is time the coachees make their mind as to which one of the options looks better to them that can help them achieve their goal. At this point in time, the role of the coach is to motivate the coachee to state exactly what they intend to do. It must be understood that it is the responsibility of the coachees themselves to execute the individual steps. The duty of the coach is to identify the signals from the coachee that shows resistance. In such scenarios, it is helpful to refer back to the first stage of outcomes for the purpose of confirming whether the objective and goal is extremely unrealistic or obscure.

Step 5: Review

By assenting to review the plan of action after a certain period of time, a little bit of pressure is applied on the coachee to take action. The critical thing for the success is the genuine conduct of the review rather than just an announcement. It is essential to take the first step in the near future in order to avoid losing the planned actions in the daily activities of the business. For that reason, the momentum for the forthcoming actions can stay consistent. The senior-level personnel or the coach can take help of the review in order to keep the obligation and track the coachee's progress and can also regard it as, for instance, for their own superior. The coach ultimately continues to maintain control, and the coachees becomes capable of achieving clarity regarding their own activities.

Visual Management

Hej there! Great to have you back! In this article we want to show how visual management can help you to keep track in daily operations.

Generally speaking Lean Management can be seen as a clearly organized workflow that defines the way your organization should work following given principles. Above all principles existing lies to avoid waste in any kind following the 5S Principle as foundation: 1 Sort out 2 Set in order 3 Shine 4 Standardize 5 Sustain.

For a clear visualization of running process in your organization, cleanliness and orderliness is the main part of it. Clarity of your processes on the shop floor is the foundation for all lean manufacturing activities. Having the clarity the implementation and maintaining of visual management methods will guide you to a real state of flow.

In the following we want to describe key basic visual management elements that every production, following the lean principles, should have.

Boards, Notes, Infographics, Brochures and even Movies

Don’t panic and try to explain all those Japanese words it works well without being too technical. Many instruments of the Lean Manufacturing Methodology are very useful to raise the awareness of your employees about lean management. Once implemented and continuously driven by the management the incentives are there to drive daily improvement measures.

The target with visual management and those methods are all the same:

1. Create transparency

2. Visual representation of procedures processes and services

3. Making problems (or bottlenecks) visible

Kanban Boards

Kanban can be literally translated as “card” in the context of a production system. No matter what processes you have, it all starts with a customer’s order. The Kanban card is then used to inform upstream processes about the need of materials, pre-assemblies or process steps. This automatically leads to a cycle that triggers itself through the complete value creation chain.

This is the so called pull principle the advantage if this principle is that, in best case, you have no work in progress which means you have no stock of semi finished goods built up, because only what the following process steps need is produced.

A3 Reports

The term A3 Report comes simply from the size of paper which is used for the documentation of the report. The structure itself follows the PDCA methodology.

The A3 Report is the representation of a problem to be solved. In this case the responsible person from the quality department takes the A3 Report, starts the problem solving actions and follows a systematic structure that makes it possible to describe the effects that are currently leading to a deviation from the standard. Using the A3 only makes sense when you don’t know the root cause yet. If you already know the root cause don’t waste your time. Fix it and go back to normal.

Andon: Lean management with boards and ripcords.

Andon again a Japanese word meaning “lantern”, at least in the context with lean manufacturing. It is a visual aid that is there to draw attention to problems on the shop floor when machines or processes are causing defects or simply stop working.

You might think you have seen them all by walking through production and seeing all those PLC signal lamps indicating green or red, but there is so much more. Just have a look at the Andon article.

Just want to name administration, maybe there is nothing to indicate, but when you think about a document that is needed in a different department, waiting for this is one of the TIMWOODS MUDA. The time waiting is probably the best indicator to start with lean admin activities.

Andon Cords - Please pull the rip cord in an emergency!

Andon Cords are rip cords or a simple button straight at the operation on the shop floor that gives the operator in the process the possibility to instantly stop the line when problems or defects occur.

Andon Boards

Andon Boards are displays or nowadays mainly TV screens that are showing the actual status of the manufacturing line e.g. PPM, down times, etc. Typically it is automatically feeded by the machineries of the production line. With the standard defined color indication everyone sees if they are doing great or not so great. In the second case an automated alert to supervisors or maintenance is triggered.

You see there are many possibilities, but the target is always the same. One hint at the end: Make your boards, infographics or brochures as simple as possible! (or just use mine ;))
WHY? As with processes > it is only a good process when you can’t cut anything more away from it. In other words: What is the value you get from something that nobody understands?

If you take the principle of visual management seriously it will help you to bring all processes in your organization to live.