Created with Funding from WIRED NW
By the end of today’s class, you should be able to:
Use Gap Analysis methodology, Current State vs. Future State Gap Analysis
Apply Gap Analysis to your organizationApply Problem Solving techniquesConfirm stretch goals and perform gap analysis from
current state of each stretch goal
Launch an Action Plan
Gap Analysis &Action Plan Launch
Created by funding from WIRED NW
3/14/2002
ICoils5 days
I4600 L2400 R
I1100 L600 R OCT = 62 sec
D/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts
27, 600 sec. Avail.
OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts
27,600 sec. Avail.
Shipping
Staging
III1600 L850 R
1200 L640 R
2700 L1440 R
FerrousMetals Co.
500 ft coils
Tues & Thurs
Machine
1
OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts
27, 600 sec Avail.
OCT= 1 secondD/R = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeks
Stamp
200 t
Weld
1
OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts
27,600 sec. Avail.
1x daily
Sub-Assembly
1
Assembly
1
MRP
18,400 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs
2 Shifts
Highland ManufacturingSheet Metal HousingsCurrent State(Date)
Daily ShipSchedule
Weekly Schedule TT = 60 sec.
ManchesterAvenue
6-weekForecast
Weeklyfax
ProductionControlMRP
90/60/30 dayForecasts
DailyOrder
5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days
1 sec. 39 sec. 46 sec. 62 sec. 40 sec.
Lead Time=23.6 days
Process Time= 188 sec
Let’s apply gap analysis to your organization
We have collected the data along our past class sessions:
•Refer back to your Policy Deployment plans•Review your X matrix•Review your current state VSM(s)•Identify opportunities to apply Standard Work
Created by funding from WIRED NW
Three key questions:
•What are the gaps?•What are the most important?•Where are the Kaizen opportunities?
3/14/2002
ICoils5 days
I4600 L2400 R
I1100 L600 R OCT = 62 sec
D/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts
27, 600 sec. Avail.
OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts
27,600 sec. Avail.
Shipping
Staging
III1600 L850 R
1200 L640 R
2700 L1440 R
FerrousMetals Co.
500 ft coils
Tues & Thurs
Machine
1
OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts
27, 600 sec Avail.
OCT= 1 secondD/R = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeks
Stamp
200 t
Weld
1
OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts
27,600 sec. Avail.
1x daily
Sub-Assembly
1
Assembly
1
MRP
18,400 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs
2 Shifts
Highland ManufacturingSheet Metal HousingsCurrent State(Date)
Daily ShipSchedule
Weekly Schedule TT = 60 sec.
ManchesterAvenue
6-weekForecast
Weeklyfax
ProductionControlMRP
90/60/30 dayForecasts
DailyOrder
5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days
1 sec. 39 sec. 46 sec. 62 sec. 40 sec.
Lead Time=23.6 days
Process Time= 188 sec
Created by funding from WIRED NW
What are the gaps?
•Review your policy deployment plans•Review your X Matrix•Compare your goals to your current situation•Compare your Current State VSM to your goals•What in your policy deployment flows towards an opportunity for you?
3/14/2002
ICoils5 days
I4600 L2400 R
I1100 L600 R OCT = 62 sec
D/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts
27, 600 sec. Avail.
OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts
27,600 sec. Avail.
Shipping
Staging
III1600 L850 R
1200 L640 R
2700 L1440 R
FerrousMetals Co.
500 ft coils
Tues & Thurs
Machine
1
OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts
27, 600 sec Avail.
OCT= 1 secondD/R = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeks
Stamp
200 t
Weld
1
OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts
27,600 sec. Avail.
1x daily
Sub-Assembly
1
Assembly
1
MRP
18,400 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs
2 Shifts
Highland ManufacturingSheet Metal HousingsCurrent State(Date)
Daily ShipSchedule
Weekly Schedule TT = 60 sec.
ManchesterAvenue
6-weekForecast
Weeklyfax
ProductionControlMRP
90/60/30 dayForecasts
DailyOrder
5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days
1 sec. 39 sec. 46 sec. 62 sec. 40 sec.
Lead Time=23.6 days
Process Time= 188 sec
Created by funding from WIRED NW
What are the most important?
Consider :Strategic priorities
SafetyQualityCostDeliveryService
3/14/2002
ICoils5 days
I4600 L2400 R
I1100 L600 R OCT = 62 sec
D/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts
27, 600 sec. Avail.
OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts
27,600 sec. Avail.
Shipping
Staging
III1600 L850 R
1200 L640 R
2700 L1440 R
FerrousMetals Co.
500 ft coils
Tues & Thurs
Machine
1
OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts
27, 600 sec Avail.
OCT= 1 secondD/R = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeks
Stamp
200 t
Weld
1
OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts
27,600 sec. Avail.
1x daily
Sub-Assembly
1
Assembly
1
MRP
18,400 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs
2 Shifts
Highland ManufacturingSheet Metal HousingsCurrent State(Date)
Daily ShipSchedule
Weekly Schedule TT = 60 sec.
ManchesterAvenue
6-weekForecast
Weeklyfax
ProductionControlMRP
90/60/30 dayForecasts
DailyOrder
5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days
1 sec. 39 sec. 46 sec. 62 sec. 40 sec.
Lead Time=23.6 days
Process Time= 188 sec
Created by funding from WIRED NW
Where are the Kaizen opportunities?
• • • • •
And there’s more!
Created by funding from WIRED NW
Confirm stretch goals
• • • •
perform gap analysis from the current state of each stretch goal
Created by funding from WIRED NW
Narrow the Kaizen opportunities to one that you think can be deployed within the next month at your organization.
Created by funding from WIRED NW
Begin your Kaizen Charter
•Who will be your team?•How will you approach it?•What do you plan to accomplish at your company event within the next month?
Created by funding from WIRED NW
•Gather tools and supplies•Build or borrow Kaizen toolkits
•Communicate, communicate, communicate!
•Anticipate participants’ needs •Large area to gather, and later report out•Clearly articulate the current situation•Provide agenda, schedule•Provide food and beverages
Created by funding from WIRED NW
•Let the opportunity begin!
•Allow time for participants to bring back findings and prepare presentation
•Invite appropriate people to the presentation
•Top managers•People who can influence, or who will be influenced by the findings•Learners who might participate in future Kaizen events
Created by funding from WIRED NW
•Thank everyone for their participation and interest
Thank you!
Created by funding from WIRED NW
•Now it’s your turn
Created by funding from WIRED NW
Created by funding from WIRED NW
This assignment should take about 12 hours (your two hours independent assignment for this week, plus this will count in lieu of another classroom session: eight hours class time and the two hours independent assignment time for that session). 1.Meet with your mentor and review the gap analysis discussed in today’s session.2.Mutually agree on opportunities to apply what was learned today, using as many tools as possible.3.Execute a Kaizen at your organization, and prepare a 15 minute presentation to report out at next session.
Created by funding from WIRED NW
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