Professional Documents
Culture Documents
Best
Sort - when in doubt, throw it out, delete or archive Practice
5
1. Only the current levels of inventory in the area is needed for the work at hand.
2. Only the necessary items to perform the work at hand are located in the area.
3. All tools, fixtures and jigs in the area are used on a regular basis.
4. All announcements are arranged in a straight and neat manner.
5. Your general impression should tell you this is the best you have seen for a manufacturing
environment.
Best
Straighten - decide and organize where to keep necessary items Practice
5
1. Machines, benches, etc. are arranged in a logical & neat fashion to promote a smooth product
flow through the work area.
2. Lines on the floor clearly mark aisles, walkways, work areas, storage locations and danger
areas.
3. Only current labeled documents and binders necessary to do the work are stored at
workstations.
4. Tools, gages and fixtures are arranged neatly and stored, kept clean and free of any risk from
damage.
5. Equipment is properly maintained and labeled. Critical points for daily maintenance checks are
clearly marked.
Best
Shine - perform a thorough cleaning Practice
5
1. All floors are clean and free of debris, oil, and dirt. Cleaning of floors is done routinely and at
appropriate predetermined intervals.
2. Routine cleaning of machines is apparent, there is no oil, chips, scrap laying on work surfaces.
Glass view windows, guards, deflectors are clean & in place.
3. All equipment in the area is cleaned on a regular basis.
4. When unexpected delays occur, operators habitually & automatically sweep floors & wipe
equipment.
5. Where applicable, FOD prevention procedures are enforced. All loose items removed before
entering FOD prevention area. Shadow boxes kept clean.
Best
Standardize - incorporate cleaning procedures into the daily work Practice
5
1. Display boards are present in each production work area and accessible to all personnel in the
area.
2. 5S audits are performed in each work area at least monthly, results are shared with all workers
and goals for new levels set with action items.
3. PPE notices are posted in every area and all employees are wearing the required PPE's.
4. It is obvious that workers who perform similar duties, use standard methods to achieve
consistent results.
5. Methods are reviewed on a regular basis, and as new methods are developed, they are quickly
documented and adopted by others.
Best
Sustain - management and leadership to motivate and sustain Practice
5
1. Employees are adequately deployed to keep equipment operating properly. A Preventive
Maintenance program is in place and functions at a high level.
2. Each area of the operation, inside and out, falls under the responsibility of a manager with 5S
auditing and assignment authority.
3. All documents and binders are clearly labeled as to their contents. Responsibility for control &
revisions is clear. Nothing is unlabeled.
4. Responsible manager/staff person visits each work area on a regular basis and provides
feedback on 5S efforts and results.
5. Disciplined controls to assure each of above items is maintained at highest level. There is a
sense of responsibility by all employees to maintain systems.
oduction
irable
ocess or Project Name:
Minimum Many
Best in the acceptable opportunities for No Activity or,
organization level improv'mt slight effort Total
4 3 2 1
Sort 0
Minimum Many
Best in the acceptable opportunities for No Activity or,
organization level improv'mt slight effort Total
4 3 2 1
Straighten 0
Minimum Many
Best in the acceptable opportunities for No Activity or,
organization level improv'mt slight effort Total
4 3 2 1
Shine 0
Minimum Many
Best in the acceptable opportunities for No Activity or,
organization level improv'mt slight effort Total
4 3 2 1
Standardize 0
Minimum Many
Best in the acceptable opportunities for No Activity or,
organization level improv'mt slight effort Total
4 3 2 1
Sustain 0
PROCESS
Pitch Duration
OUTSIDE SOURCE
MAX PCS
CUSTOMER
C/T (s)
C/O (s)
Uptime (%)
Yield (%)
STORAGE
Quantity
Time
OUTSIDE SOURCE
Frequency
PLANNING
CONTROL
Frequency
Frequency
Frequency
Frequency
LEAD
TIME (s) 0
VALUE
TIME (s) 0
Generic Product
SUPPLIER
STORES
Frequency Daily Quantity
Time 6000
INSPECTION
GOODS-IN
Quantity
Time 6000
6000 6000
600 600
Generic Production Value Stream Map - Example Excel Generated VSM
PLANNING
PURCHASING
MANUFACTURING
CELL MANAGER
6000 6000
600 600
AWAITING FINAL INSPECTION FINISHED GOODS
Quantity Quantity
Time 6000 Time 6000
TEST INSPECTION SHIPPING
6000 6000
Frequency Daily
Frequency Daily
LEAD
6000 TIME (s) 42000
VALUE
TIME (s) 4200
Pugh Concept Evaluation Matrix
Evaluation Criteria
Total (+)
Total (s)
Total (-)
n Matrix
Exisiting
Process
Year Cost Benefits Net Benefits Description
1 Color
2 Yield Strength
3 Hardness of cookie
4 Weight
5 Size
6 Thickness
7 Cost per cookie
8
9
10
11
12
13
14
15
16
17
18
19
20
Customer Weights
Kano Type
Customer Needs
1 Good Texture 5 L
2 Generous Portions 10 L
3 Good taste 10 B
4 Low price 7 D
5 Appearance 2 B
6
7
8
9
10
11
12
13
14
15
Raw score
Scaled
Relative Weight
Rank
Best in Class
Worst in Class
Kano
Direction
Technical Requirements
9
0.117647058823529
18 Color
9
9
0.705882352941176
108 Yield Strength
3
9
0.431372549019608
66 Hardness of cookie
1
0.065359477124183
10 Weight
9
9
1 153 Size
3
0.196078431372549
30 Thickness
9
9
1 153 Cost per cookie
20%
12%
28%
28%
3%
2%
6%
6 3 4 7 1 5 1
Yellow 1.0 g/cm
Survey Legend
A Current product
B Competitor B
C Competitor C
A
1 Poor
A
B
2
B
A
B
A
C
3 Acceptable
B
A
C
C
4
B
C
5 Excellent
Copyright © 2005 Kevin Otto
Please freely distribute and modify, but properly reference and maintain this contact information in the sheet.
www.robuststrategy.com
kevin_n_otto@yahoo.com
http://www.kevinotto.com/RSS/templates/QFD Template.xls
Modified from a template from Design4X Inc.
RACI Matrix Template
Role
Role #1
Role #2
Role #3
Role #4
Role #5
Role #1
Role #2
Role #3
Role #4
Role #5
Role #1
Role #2
Project Deliverable
(or Activity)
RACI Definitions:
Responsibility = person or role responsible for ensuring that the item is completed
Accountable = person or role responsible for actually doing or completing the
item
Consulted = person or role whose subject matter expertise is required in order to
complete the item
Informed = person or role that needs to be kept informed of the status of item
completion
Role #4
Project Sub-Teams
Role #5
Role #1
Role #2
Role #3
Role #4
External Contributors
Role #5
Show Gantt for Actual Show Status?
█
Planned Actual %
# List of Start Dur Start Dur Done 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
1 Activties
Activity 1 1 5 1 2 0%
2 Activity 2 1 5 1 6 58%
█
███
██
█
3 Activity 3 2 4 2 5 35%
4 Activity 4 4 8 2 6 10%
5 Activity 5 4 1 3 8 0%
6 Activity 6 4 3 4 6 0%
7 Activity 7 5 4 4 3 0%
8 Activity 8 5 2 4 5 0%
9 Activity 9 5 2 4 6 0%
10 Activity 10 6 5 6 7 0%
11 Activity 11 6 1 7 8 0%
12 Activity 12 9 3 8 3 0%
13 Activity 13 9 6 8 6 0%
14 Activity 14 9 3 9 1 0%
15 Activity 15 9 4 9 4 0%
16 Activity 16 10 5 10 2 0%
17 Activity 17 11 2 10 5 0%
18 Activity 18 12 6 11 7 0%
19 Activity 19 12 1 11 5 0%
20 Activity 20 14 5 11 6 0%
21 Activity 21 14 8 11 1 0%
22 Activity 22 14 7 11 3 0%
23 Activity 23 15 4 12 8 0%
24 Activity 24 15 5 14 3 0%
25 Activity 25 15 8 14 5 0%
26 Activity 26 16 8 15 1 28%
██
27 Activity 27 17 2 15 2 60%
████
28 Activity 28 17 1 16 8 25%
█
29 Activity 29 17 5 16 3 5%
30 Activity 30 18 1 16 3 16%
31 Activity 31 18 1 17 4 3%
█
32 Activity 32 19 6 18 7 41%
█
█
█
33 Activity 33 19 6 21 5 31%
█
34 Activity 34 21 8 22 7 0%
35 Activity 35 21 1 23 3 0%
36 Activity 36 23 4 24 6 0%
37 Activity 37 24 1 24 3 0%
38 Activity 38 24 6 24 5 0%
39 Activity 39 24 7 24 8 0%
40 Activity 40 24 3 24 2 0%
What is current week? 3
22 23 24 25 26 27 28 29 30 31 32
█
The Cause and Effect matrix is used to understand the relationship between KPIVs and KPOVs. It can help initiate
The KPIVs are inputs to vary and record, the KPOV is a response to measure. These experiments, natural or DOE,
The C&E matrix also provides the initial input to the process FMEA. Whenever a KPOV drifts out of specification, th
When that happens, the CE matrix should have listed whatever the "Cause" was, as a KPIV going out of specificatio
Customer
Importance
Customer Rank 10 5 3
1 2 3 4
Delivery
Delivery
Packagi
Defects
Process Hours
Cost
ng
Step KPIV
Delivery
1 Step 1 9 1 1
allocation time
2 Delivery units 5 9 9
Process Steps & Key Process Input Variables
3 Step 2 # Resources 1 9 9
4 Experience 1 9 5
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Reverse Total 0 0 0 0
Reverse Score 0 0 0 0
Reverse Rank 1 1 1 1
35 25 30
$2 $5
50 00
Target
2
LSL
$1
00
USL
0
Please freely distribute and modify, but properly reference and
5 6 7 8 9 10 11 12 13 14
0
0
1
© 2005 Kevin Otto
kevin_n_otto@yahoo.com www.kevinotto.com
nd modify, but properly reference and maintain this contact information in the sheet.
http://www.kevinotto.com/RSS/templates/C&E Matrix.xls
15
2 98
1 122
3 82
4 70
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.
Notes:
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
For information on the theory and constants used in the form see MSA Reference Manual, Third edition.
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
* D4 =3.27 for 2 trials and 2.58 for 3 trials. UCLR represents the limit of individual R's. Circle those that are
beyond this limit. Identify the cause and correct. Repeat these readings using the same appraiser and unit as originally used or
discard values and re-average and recompute R and the limiting value from the remaining observations.
Notes:
GAGE REPEATABILITY AND REPRODUCIBILITY DATA SHEET
VARIABLE DATA RESULTS
Part Number Gage Name Appraiser A
For information on the theory and constants used in the form see MSA Reference Manual, Third edition.
Master Appraiser Op1_Trial Within Op1 with Op2_ Op2_
Test Samples Rating 1 Op1_ Trial 2 Op1 standard Trial1 Trial 2
1 Okay Okay Okay 1 1 Okay Defective
2 Okay Okay Defective 0 0 Defective Okay
3 Defective Defective Defective 1 1 Defective Defective
4 Defective Defective Defective 1 1 Defective Defective
5 Okay Okay Defective 0 0 Okay Okay
6 Defective Defective Defective 1 1 Defective Defective
7 Defective Defective Defective 1 1 Defective Defective
8 Defective Defective Defective 1 1 Defective Defective
9 Defective Defective Defective 1 1 Defective Defective
10 Okay Okay Okay 1 1 Okay Okay
11 Okay Okay Defective 0 0 Okay Okay
12 Okay Okay Okay 1 1 Defective Defective
13 Defective Okay Okay 1 0 Defective Defective
14 Defective Defective Defective 1 1 Defective Defective
15 Okay Okay Okay 1 1 Okay Okay
16 Defective Defective Defective 1 1 Defective Defective
17 Defective Defective Defective 1 1 Defective Defective
18 Defective Defective Defective 1 1 Defective Defective
19 Defective Defective Defective 1 1 Defective Defective
20 Okay Okay Okay 1 1 Okay Okay
# Matched 17 16
# Inspected 20 20
% Agree 85.00% 80.00%
Within Op2 with Between Ops All Ops vs
Op2 standard Match Standard
0 0 0 0
0 0 1 0
1 1 1 1
1 1 1 1
1 1 0 0
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 0 0
1 0 0 0
1 1 0 0
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
18 17 15 14
20 20 20 20
90.00% 85.00% 75.00% 70.00%
Confidence Level (Power) 95% Confidence Factors
Confidence Interval 0.05 Percent
Population (if known) 700 80%
85%
Attribute Data 90%
Percent defects (50%) 50% 95%
Sample Size (Unknown Population) 384 96%
Sample Size for Known Population 248 97%
98%
Variable Data 99%
Standard Deviation ([High-Low]/6) 0.167 Defaults
Sample Size (Unknown Population) 43 0.05
Sample Size for Known Population 41 50%
0.167
Confidence Factors
Z
1.28 Variable Data Example From Juran QC Handbook pg 23.
1.44 Sampling to determine battery life
1.64 Estimate must be within 2 hours (confidence interval) of tru
1.96 Standard Deviation = 10.0 hours
2.06 95% confidence level
2.17 n= 96
2.33
2.58 Example 2 - Determine Average Part Length
Most production between 2.009 (low) and 2.027 (high) inch
Confidence Interval (desired width) Estimate Stdev as (2.027-2.009)/6 = .003 inches
Percent defects (Attribute - 50%) Confidence interval = +/- 0.001
Standard Deviation ([High-Low]/6) n=35
Juran QC Handbook pg 23.50
ge Part Length
9 (low) and 2.027 (high) inches
)/6 = .003 inches
Enter process sigma level, compute PPM
Process Sigma Level -> 6
PPM 3.4
Percent 0.00034%
Total 376
141376
The Squares Table
49 49 225 121 81
144 289 144 324 324
196 324 324 361 361
361 625 484 361 529
49 100 121 225 121
15.04 Average
5655.04
2.866081402016
Degrees of Mean
Source of Variation Sum of Squares Freedom Squares Fo Fcrit Status
Polyster Weight % 475.56 4 118.89 14.75062 2.866081 Reject Null
Error 161.2 20 8.06
Total 636.76