Charts and Graphs - Marek on Lean · 2011. 1. 7. · Charts and Graphs Marek Piatkowski January...
Transcript of Charts and Graphs - Marek on Lean · 2011. 1. 7. · Charts and Graphs Marek Piatkowski January...
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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”
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T
O
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L
No Customer Issues
Customer Issue
COLORED LEGEND:
GREEN RED
MONTH YEAR DEPARTMENT
__________ ________ _______________
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Marek Piatkowski – FSP Consulting Inc.
DELIVERY
Month Year Line
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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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Marek Piatkowski – FSP Consulting Inc.
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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Marek Piatkowski – FSP Consulting Inc.
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SAFETY
Month-
_____
Year-
2000
Line- ______
A SAFE DAY = GREEN
AN OSHA RECORDABLE EVENT = YELLOW
A LOST DAY OCCUPATIONAL INJURY =RED
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Marek Piatkowski – FSP Consulting Inc.
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Marek Piatkowski – FSP Consulting Inc.
LINE ISSUES BOARD
Completion
Date
Assigned to Status / Update
Target
Date
Date
Location of
Problem
Description of Problem
Identified
by
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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%
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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%
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100% Part #:
95%
90%
85%
80%
75%
70%
65%
60%
55%
50%
45%
40%
35%
30%
25%
20%
15%
10%
5%
0%
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Marek Piatkowski – FSP Consulting Inc.
GOAL=_______PPMFIRST TIME THROUGH QUALITY (Daily)
PP
M
MONTH YEAR DEPT Delphi Confidential
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TOTAL INSPECTED
TOTAL REJECTED
TOP CAUSES
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Marek Piatkowski – FSP Consulting Inc.
Weekly Scrap Chart Manufacturign Cell: Week Ending:
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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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Marek Piatkowski – FSP Consulting Inc.
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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Marek Piatkowski – FSP Consulting Inc.
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
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368
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352
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336
40
320
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304
36
288 288
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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
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112 112 112
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96
96
96
10
80
80
80
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64
64
64
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48
48
48
4
32
32
32
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Model ACM 138 ACM 251 ACM 031
D-817 Finished Goods Buffer
Updated by, date & time:
Inventory LevelsInventory Levels
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Marek Piatkowski – FSP Consulting Inc.
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:
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2
1
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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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Marek Piatkowski – FSP Consulting Inc.
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.
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Marek Piatkowski – FSP Consulting Inc.
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%)
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Marek Piatkowski – FSP Consulting Inc.
PARTS/OPERATOR/100 HRS (Daily)
GOAL = ______
MONTH________ YEAR_____ DEPT.( A REA ) _______
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DAY X 100
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Marek Piatkowski – FSP Consulting Inc.
Weekly Lost Time Chart Manufacturign Cell: Week Ending:
Minutes
480
460
440
420
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380
360
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320
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280
260
240
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200
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120
100
80
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20
0
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Marek Piatkowski – FSP Consulting Inc.
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
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Day of the Month
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Marek Piatkowski – FSP Consulting Inc.
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.
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Marek Piatkowski – FSP Consulting Inc.
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