THE PRAGMATIC FMSTRUCTURED - FOCUSED - INTENTIONAL
PURPOSED - TECHNICAL MANAGEMENT
TOPICS – PRACTICAL APPROACH TO IMPROVEMENTS
• Poka-Yoke (Mistake Proofing)
• Kaizen
• 5S
• Lean Six Sigma (Lean Sigma, Lean Manufacturing)
• TQM / 3P
POKA-YOKE
• To avoid (yokeru) - inadvertent errors (poka)
• Japanese - mistake proofing
• Prevents incorrect assembly
• Easily identifies flaws
• Step one of complete error-proofing
• Designed to prevent incorrect performance
POKA-YOKE
• Attempt on the cheap
• Simpler is better
• Not optional
• Information alone is not mistake proofing
• No decision making
THINK OF A FACILITIES EXAMPLE
• What is being done here
• What is the problem
• Could problem be further mistake proofed
WHAT ELSE NEEDS ERROR PROOFING
• Possible problem that can be error proofed in a restroom
• Custodial labor related to restroom cleaning
COMPARE TO FACILITIES EXAMPLE
• What is problem
• How could it be further mistake proofed
• How could you use something like this in facilities (room set-up diagrams)
KAIZEN• Japanese word: Kai = Change Zen=Good
• Continuous Improvement
• Eliminate waste by improving standardized processes
• Going beyond simple productivity improvement
• Performed correctly, the process:
• Humanizes the workplace
• Eliminates overly hard work
• Teaches people how to spot and eliminate waste
KAIZEN
• Identify an opportunity
• Analyze the process
• Develop an optimal solution
• Implement the solution
• Study the results
• Standardize the solution
• Plan for the future
KAIZEN
• Replace conventional fixed ideas with fresh ones.
• Start by questioning current practices and standards.
• Seek the advice of many associates before starting a Kaizen activity.
• Think of how to do something, not why it cannot be done.
• Don’t make excuses. Make execution happen.
• Do not seek perfection. Implement a solution right away, even if it covers only 50 percent of the target.
• Correct something right away if a mistake is made.
KAIZEN
• One day or week long
• Whole team involved
• Stop regular work
• Provide incentive and tools
• Change immediately implemented
• Short but effective at small improvement
• Smaller part of continuous improvement
KAIZEN FACILITIES EXAMPLES FOR FMS
• Every teammate involved / influence
• Provide tools / framework / basic goals
• Give out a reminder to mark change
• Have a Picnic BBQ
• Be satisfied with small improvements
5S• The S’s stand for:
• Seiri or sort
• Seiton or straighten
• Seiso or shine
• Seiketsu or standardize
• Shitsuke or sustain
System - instilling order and cleanliness in the workplace
5S
5S – ALTERNATIVETERMS
• Sorting
• Systematic arrangement
• Spic and span
• Standardize
• Self-discipline
• Put things in order
• Proper arrangement
• Clean
• Purity
• Commitment
Before 5S After 5S
5S Facilities Example:
• Know what is missing • Know what is running
low• Know what is clean• Prevent forgetting a tool• Cleans off the cart• Color Coded for Use• Quicker to Find
LEAN – TENDS TO FOCUS ON SPEED
• Value – from customer view
• Value Steps – eliminate non-value steps
• Flow – tight sequence
• Pull – customer requests
• Perfection – when no waste based on customer
LEAN -PRODUCTION / MANUFACTURING / ENTERPRISE
• Zero waiting time
• Zero Inventory
• Scheduling — internal customer pull instead of push system
• Batch to Flow — cut batch sizes
• Line Balancing
• Cut actual process times
LEAN FACILITIES AREAS OF FOCUS
• Overproduction
• Queues
• Transportation
• Inventory
• Motion
• Over processing
• Defective product
LEAN FACILITIES EXAMPLES FOR FMS
• Electricity Usage
• Room Set-up
• Landscaping
• Custodial Efforts
• Team Uniforms
SIX SIGMA – FOCUS ON QUALITY
• 3.4 defects per million chances
• Increase profits
• Eliminate variables, defects and waste
• Improve customer satisfaction
• Use facts, data and analysis
SIX SIGMA
• Define
• Measure
• Analyze
• Design
• Control / Verify
6 SIGMA – FACILITIES SIMPLIFIED
• Customer Complaint?
• How can you quantify – run a test with data
• Brain storm how to improve it, chose best improvement
• Remeasure with same points - partial process or test process
• Implement improvement on whole process – confirm new data
• Control or Sustain Improvement – verify with data
SIX SIGMA TOOLSDefine Measure Analyze Implement Control
EXAMPLE LEAN SIGMA – EL PASO PARKS AND REC
• Pareto analysis - 70% of all wo’s on heads and valves
• Top solutions:• Implement 5S – standardized stock vans, corrals and warehouse
• Create satellite storage areas - reduce travel time
• Use a groundskeeper as a “runner” working with the material supervisor
• Reassign work area zones to match material / stock locations
• Goal: Reduce the repair time & cost / work order by 33%.
• Results: Reduction by 92%.• Time / irrigation repair work order reduced from 24 hours to only 1.81 hours
• Cost / work order decreased from $297.36 to $22.40, estimated annual cost avoidance of $78,089 in payroll costs
6 SIGMA FACILITIES EXAMPLES
• Work Order Response Time
• Customer Satisfaction Survey Results
• Number of Reworks
• Number of Too Hot Too Cold Calls
• Energy Cost
• Fuel Cost
TQM
• Ethics & Integrity
• Trust
• Leadership
• Teamwork
• Training
• Recognition
• Communication
3P
• People:
• Internal and external
• Product:
• Required specs
• Process:
• Continuous improvement
MULTIPLE DIVERSE COMBINATIONS• Total Lean Six Sigma Integration - with tools
• Diverse
• Complex
• High Level
• Broad
• Long term
CONDENSE / BASIC LESSONS FOR FMS
• Lead - actively engaged
• Thoughtful – use tools
• Others - involve the team
• Real Data / Facts
• Focus – improvements, goal, mission
• Never Quit – closed loop
BIBLICAL LESSONS
• Not growing - then dying
• Include others – Refuse the Credit
• Take a Sabbath – switch gears
• Remember the Past – Similar thing have already been done
• Walk by Faith
DISCUSSION
• How can an FM be pragmatic about improvements?
• Quality, Speed, Customer Satisfaction, Cost
• Which is most important?
• What have you begun?
• Share Successes
REFERENCES
• https://www.isixsigma.com/
• http://texasleansixsigma.com/city-of-el-paso-irrigation-repair/
• http://www.lc-stars.com/people-process-product.html
• https://www.lean.org/
• God’s Word
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