Charts and Graphs - Marek on Lean · 2011. 1. 7. · Charts and Graphs Marek Piatkowski January...

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1 Marek Piatkowski – FSP Consulting Inc. Information Centers Information Centers Charts and Graphs Charts and Graphs Marek Piatkowski January 2011

Transcript of Charts and Graphs - Marek on Lean · 2011. 1. 7. · Charts and Graphs Marek Piatkowski January...

Page 1: Charts and Graphs - Marek on Lean · 2011. 1. 7. · Charts and Graphs Marek Piatkowski January 2011. Marek Piatkowski – FSP Consulting Inc. 2 THE QUALITY “Q ...

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Marek Piatkowski – FSP Consulting Inc.

Information CentersInformation Centers

Charts and GraphsCharts and Graphs

Marek Piatkowski

January 2011

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Marek Piatkowski – FSP Consulting Inc.

THE QUALITY “Q”

1 2

4

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T

O

T

A

L

No Customer Issues

Customer Issue

COLORED LEGEND:

GREEN RED

MONTH YEAR DEPARTMENT

__________ ________ _______________

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DELIVERY

Month Year Line

1 2

3

4

5

6

7

8

9

10

11

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1314

31

30

29

28

27

26

23

22

21

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19

25

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THE

DELIVERY

“D”

COLOR LEGEND

GREEN = NO MISSED SHIPS

OR PREMIUM

RED = MISSED SHIPS

OR PREMIUM FREIGHT

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Marek Piatkowski – FSP Consulting Inc.

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350

STATORS CASTINGS POTTES

350

700 700

STOCK DE SECURITE ALTERNATEUR LIQUID COOLED

Besoin 3300 pour

re-aménagement

Besoin 400 pour

re-aménagement

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1 2 3

4 5 6

7 8 9 10 11 12 13

14 15 16 17 18 19 20

21 22 23 24 25 26 27

28 29 30

31

SAFETY

Month-

_____

Year-

2000

Line- ______

A SAFE DAY = GREEN

AN OSHA RECORDABLE EVENT = YELLOW

A LOST DAY OCCUPATIONAL INJURY =RED

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LINE ISSUES BOARD

Completion

Date

Assigned to Status / Update

Target

Date

Date

Location of

Problem

Description of Problem

Identified

by

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Monthly Productivity Chart Month:

100% Part #:

95%

90%

85%

80%

75%

70%

65%

60%

55%

50%

45%

40%

35%

30%

25%

20%

15%

10%

5%

0%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

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Marek Piatkowski – FSP Consulting Inc.

Monthly Productivity Chart Month:

100% Part #:

95%

90%

85%

80%

75%

70%

65%

60%

55%

50%

45%

40%

35%

30%

25%

20%

15%

10%

5%

0%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

100% Part #:

95%

90%

85%

80%

75%

70%

65%

60%

55%

50%

45%

40%

35%

30%

25%

20%

15%

10%

5%

0%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

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GOAL=_______PPMFIRST TIME THROUGH QUALITY (Daily)

PP

M

MONTH YEAR DEPT Delphi Confidential

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

TOTAL INSPECTED

TOTAL REJECTED

TOP CAUSES

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Weekly Scrap Chart Manufacturign Cell: Week Ending:

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

1 Destruct 11 Lamination 21 Rerun

2 End/Start of coil 12 Mis-hit 22 Broken/chipped die

3 Marks on surface 13 Purchased material 23 Old level parts

4 Bent 14 Setup scrap 24 Handling damage

5 Out of tolerance 15 Defective welds 25 Missing holes

6 Feed off 16 Welds burned hole 26 Holes off location

7 Misformed 17 Auto welder/bent 27 Scrap in die

8 Misgauged 18 Short or no trim 28 Tool room work

9 Rust 19 Bad nuts/threads 29 Defective component part

10 Cracking 20 Overlap

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Line: Weekly Production Schedule Week of:

Prod.

Day Sched. Actual +/- Sched. Actual +/- Sched. Actual +/- Sched. Actual +/-

YF1T-13A803-AC

Mon. YL3T-13A803-AB

YF1T-13A803-AC

Tues. YL3T-13A803-AB

YF1T-13A803-AC

Wed. YL3T-13A803-AB

YF1T-13A803-AC

Thurs. YL3T-13A803-AB

YF1T-13A803-AC

Fri. YL3T-13A803-AB

YF1T-13A803-AC

Sat. YL3T-13A803-AB

Part #

2nd Shift 3rd Shift Accum. Weekly Totals1st Shift

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Model ACM 138 ACM 251 ACM 031

Max Packs 16 50 36

Max Pcs. 128 400 288

Min Packs 12 36 28

Min Pcs. 96 288 224

# of Packs # of Pcs. # of Pcs. # of Pcs.

50

400

48

384

46

368

44

352

42

336

40

320

38

304

36

288 288

34

272 272

32

256 256

30

240 240

28

224 224

26

208 208

24

192 192

22

176 176

20

160 160

18

144 144

16

128 128 128

14

112 112 112

12

96

96

96

10

80

80

80

8

64

64

64

6

48

48

48

4

32

32

32

2 16 16

16

Model ACM 138 ACM 251 ACM 031

D-817 Finished Goods Buffer

Updated by, date & time:

Inventory LevelsInventory Levels

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SEMAINE :

130

pièce tombée

140

pièce d'essai méthodes

150

pièce d'essai qualité

160

mélange pièces / obsolètes

170

avarie de transport / stock

180

pièce cassée au montage

324

diamètre intérieur tôles NC

326

tôle décalée sur stator bobiné

331

scrap fil écrasé

332

scrap fil croisé

333

scrap fil court

334

scrap fil coupé

335

scrap masse stator

336

scrap résistance stator

337

torsadage NC

338

court circuit bobine

339

scrap surge

TOTAL SCRAP

60 38 18

cause

L M M TOTALJ V S D

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Marek Piatkowski – FSP Consulting Inc.

Pareto Analysis of Top Problems Manufacturign Cell: Week Ending:

24

23

22

21

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

1 2 3 4 5 6 7 8 9 10 11

1 Handling damage 5 Paint Defects 9 Rust

2 Bad nuts/threads 6 Defective welds 10 Cracking

3 Manpower Shortage 7 Misformed 11 Lamination

4 Equipment Down 8 Old level parts 12 Setup scrap

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Daily Production Report

Date: Work Centre / Part #:

Time Schedule Actual Variance Reason / Time Lost

6:30-7:30 85 84 -1

7:30-8:30 85 85 0

8:30-9:30 65 63 -2

9:30-10:30 85 85 0

10:30-11:30 85 85 0

12:00-1:00 42 39 -3

1:00-2:00

2:00-3:00

Totals 447 441 -6

Team Leader Report:

TOP 5 PRODUCTION PROBLEMS:

1.

2.

3.

4.

5.

Page 18: Charts and Graphs - Marek on Lean · 2011. 1. 7. · Charts and Graphs Marek Piatkowski January 2011. Marek Piatkowski – FSP Consulting Inc. 2 THE QUALITY “Q ...

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Daily Production Report

Date: Work Centre / Part #:

Time OPTIMUM Schedule Actual Variance Reason / Time Lost

6:30-7:30 100 85 84 -1

7:30-8:30 100 85 85 0

8:30-9:30 80 65 63 -2

9:30-10:30 100 85 85 0

10:30-11:30 100 85 85 0

12:00-1:00 50 42 39 -3

1:00-2:00

2:00-3:00

Totals 447 441 -6

Maximum possible number to produce

under perfect conditions

Possible number to produce under

current conditions (today @ 85%)

Page 19: Charts and Graphs - Marek on Lean · 2011. 1. 7. · Charts and Graphs Marek Piatkowski January 2011. Marek Piatkowski – FSP Consulting Inc. 2 THE QUALITY “Q ...

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PARTS/OPERATOR/100 HRS (Daily)

GOAL = ______

MONTH________ YEAR_____ DEPT.( A REA ) _______

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

DAY X 100

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Weekly Lost Time Chart Manufacturign Cell: Week Ending:

Minutes

480

460

440

420

400

380

360

340

320

300

280

260

240

220

200

180

160

140

120

100

80

60

40

20

0

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

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Month Daily Production Results - Line Shift

900

890

880

870

860

850

840

830

820

P

810

a

800

r

790

t

780 Target

s

770

760

p

750

e

740

r

730

720

H

710

o

700

u

690

r

680

670

660 x

650

640 x

630

620

610

600

590

580

570

560

550 N/W N/W

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Day of the Month

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Production Lost Time Chart Part #: Month:

Time (Minutes) Week 1 Week 2 Week 3 Week 4 Monthly Total

600

580

560

540

520

500

480

460

440

420

400

380

360

340

320

300

280

260

240

220

200

180

160

140

120

100

80

60

40

20

0

1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7 1 2 3 4 5 6 7

Reasons for Lost Time: 2. Welder down 5.

1. parts shortage 3. Manpower shortage 6.

4. 7.

Page 23: Charts and Graphs - Marek on Lean · 2011. 1. 7. · Charts and Graphs Marek Piatkowski January 2011. Marek Piatkowski – FSP Consulting Inc. 2 THE QUALITY “Q ...

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Weekly Attendance Tracking

Monday Tuesday Wednesday Thursday Friday Saturday Sunday

A

Shift

People Required to Run 24 24 24 24 24 12

-

Actual Present 21 22 24 24 23 12

Call In/No Show

-3 -2 0 0 -1 0

B

Shift

People Required to Run 18 18 18 18 18 5 -

Actual Present 17 16 18 18 18 4

Call In/No Show

-1 -2 0 0 0 -1

C

Shift

People Required to Run 12 12 12 12 12 0 0

Actual Present 10 12 10 11 12 0

Call In/No Show

-2 0 -2 -1 0 0

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Marek Piatkowski – FSP Consulting Inc.

Lean Transformation SolutionsLean Transformation Solutions

Marek PiatkowskiMarek Piatkowski

F.S.PF.S.P. Consulting Inc.. Consulting Inc.

VM: 416VM: 416--235235--26312631

Cell: 248Cell: 248--207207--04160416

[email protected]@rogers.com

www.TWIwww.TWI--Network.comNetwork.com