HR & ACC Services
VPS
1
HR & ACC Services
Key ideas of TPS/Lean/VPS:
Create value for the customer
Systematic elimination of non-value adding activities (waste) through everyone's involvement
1933 Toyota Motor
Founded
1950 Start of
TPS
1960s Supplier develop
1980s Transplants
1908 1st Model T
1913 1st moving
line
1923 2.1 million cars/year
Source: OS&E Practice et al
1890 Toyoda
loom invented
2007 VPS Launch
VPS is developed based on TPS
Production driven by cash flow
Focus on value adding flow and lead time reduction
Production driven by economies of scale
Focus on added cost
Inflexible batch production
2
HR & ACC Services
VPS Pyramid
3
VPS is a system. VPS principles creates
a mindset, a way of working and a culture.
HR & ACC Services
4
Vision:
“Giving the customer what they want, when they want it with minimum waste”
”All we are doing is to shorten the time line from the point where
we receive the customer order to the point we get paid. We shorten this time line by reducing waste in form of activities
that does not add value to our customers products.” Taiichi Ohno
Commitment:
HR & ACC Services
Inventory
Overproduction Transport
Defects and Rework Unnecessary Processes
Movements Wait
Types of Wastes
+ Not used employee creativity
5
HR & ACC Services
6
Key Elements of VPS Roll-Out in ACC
HR & ACC Services
Basic Conditions
7
Team & Process
HR & ACC Services
Top 5 & Dashboard
The Board The team
8
HR & ACC Services
Dashboard
9
HR & ACC Services
QRQC The process
Volvo Production System
ANDON, Product, Audit, Customer
QRQC
Quick,
On a Daily Base
With the Partners
On the real
Place
With real data
Escalating
If needed
• Detect and communicate defects and dysfunctions. DETECTION
• Describe them with precision DESCRIPTION
• Correct them before product deliveries. CUSTOMER PROTECTION
• Enquire to find the root cause ANALYSIS • Define and implement corrective actions on
the root cause and to improve the detection CORRECTIVE ACTIONS
• Defects Recurrency measurement ACTIONS EFFICENCY VERIFICATION
• Lesson learned CAPITALISATION
PROBLEM
SOLVING
10
HR & ACC Services
Root cause analysis Concept
Volvo Production System
ROOT CAUSE =
• The causal or contributing factors that, if corrected, would prevent recurrence of the identified problem
• The “factor” that caused a problem or defect and should be permanently eliminated through process improvement
• The factor that sets in motion the cause and effect chain that creates a problem
• The “true” reason that contributed to the creation of a problem, defect or non-conformance
11
HR & ACC Services Operational Excellence Office 12
Heart of dashboard = Action Plan PDCA
1. Plan
3. Check
4. Act
2. Do
Evaluate the results
Correct deviations and standardize solution
Identify and analyse the problem, develop and plan implementation of solution
Implement the solution
Standardize & Improve
12
HR & ACC Services
What is Gemba Walk?
• Gemba, Japanese term for "The real place" - The Gemba is where promises made to customers are either fulfilled or broken
• Main objectives
– 1. Escalation
– 2. Secure the vision for site is being secured
• The 4 “E’s” for gEnba
– Engagement
– Empower
– Encourage
– Enable
13
HR & ACC Services
Gemba Walk – Target Style?
14
HR & ACC Services
Summary of 2013 - Greensboro
15
HR & ACC Services
16
”It is common sense to take a method and try it. If it fails, admit it frankly and try another. But above all, try something.”
Franklin Roosevelt
16
HR & ACC Services
Questions
17
Top Related