LEAN - Diagnosis - Before and After

BFR AFTR
1.0 Inventory Response X
0%-6% ###
For the categories of Finished Goods, Work-In-Process 7%-55% ###
(WIP) and Purchased/Raw Materials, what portion of middle
1.1 and upper managers can state from memory the current 56%-80% X ###
turnover and the purpose of each type? 81%-93% ###
94%-100% ###
0-3 ###
4-6 ###
What is the overall inventory turnover, including Finished
1.2 Goods, WIP and Purchased/Raw material? 7-12 X ###
13-24 ###
25+ ###
<=1.0 ###
1.1-2.0 ###
What is the ratio of Inventory Turnover to the industry
1.3 average? 2.1-4.0 ###
4.1-8.0 ###
8.1+ X ###
###
2.0 The Team Approach Response X X
Exploitive ###
Bureaucratic ###
2.1 What is the organization type? Consultive ###
Participative X ###
Highly Participative ###
Individual Incentive ###
Hourly Wage ###
How are workers on the factory floor
2.2 compensated? Group Incentive ###
Salary X ###
Salary+Annual Bonus ###
Transfers & Layoffs Every
Retraining Year
Reduce ###
2.3 To what extent do people have job security? Layoffs ###
Layoffs Are Rare X ###
31%+ ###
14%-30% ###
2.4 What is the annual personnel turnover 7%-11% X ###
3%-6% ###
0%-2% ###
<5% ###
What percentage of personnel (ALL Personnel) 6%-10% ###
2.5 have received at least eight hours of 11%-30% ###
teambuilding training? 31%-90% X ###
91%-100% ###
<5% ###
What percentage of personnel are active 6%-10% ###
2.6 members of formal work teams, quality teams, 11%-30% ###
or problem-solving teams? 31%-90% X ###
91%-100% ###

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 ###
3.0 Processes Response X X
4+ ###
How many large-scale machines or single- 3 ###
3.1 process areas are in the plant through which 2 X ###
50% or more of different products must pass? 1 ###
0 ###
Large Scale ###
How would you rate the overall bias of the
3.2 plant's process selection with respect to scale? Medium/Mixed X ###
Small Scale ###
Very Difficult ###
How easy is it to shift output when the product
3.3 mix changes? Moderately Difficult X ###
Easy ###
Very Difficult ###
How easy is it to alter the total production rate
3.4 by +/-15%? Moderately Difficult X ###
Easy ###
96%-100% ###
91%-95% ###
What is management's target operating capacity
3.5 for individual departments or machines? 86%-90% X ###
76%-85% ###
50%-75% ###
How would you rate the overall bias of the Complex Technologies ###
3.6 plant's process selection with respect to Moderate/Mixed X ###
technology level? Simple Technologies ###
###
4.0 Maintenance Response X X
Describe equipment records and data. Include Non-Existent ###
4.1 records of uptime, repair history, and spare Substantially Complete X ###
parts. Include repair and parts manuals. Complete & Accurate ###
71%-90% ###
Excluding new installations and construction 51%-70% ###
4.2 projects, what percentage of maintenance hours 26%-50% ###
is unplanned, unexpected, or emergency? 11%-25% X ###
0%-10% ###
No PM ###
1%-10% Coverage ###
Does maintenance have and follow a defined
4.3 preventive schedule? 11%-30% Coverage ###
31%-90% Coverage X ###
91%+ Coverage ###
Frequently ###
Do equipment breakdowns limit or interrupt
4.4 production? Occasionally X ###
Rarely ###
Unknown ###
0%-75% ###
What is the overall average availability of plant
4.5 equipment? 76%-90% X ###
91%-95% ###
96%-100% ###

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 ###
5.0 Layout & Handling Response X X
71%-100% ###
46%70% ###
What portion of total space is used for storage
5.1 and material handling? 30%-45% X ###
16%-30% ###
0%-15% ###
71%-100% ###
What portion of the plant space is organized by
46%70% X ###
5.2 function or process type? 30%-45% ###
16%-30% ###
0%-15% ###

Pallet-size (or larger) loads, long

distances (>100'),complex flow
patterns, confusion, & lost
material ###

How would you characterize material

5.3 movement? Mostly tote-size loads, bus-route
transport, & intermediate
distances ###

Tote-size or smaller loads, short X

distances (<25'), simple & direct
flow pattern ###
Messy, Filthy, Confused ###
###
How would you rate overall housekeeping and
5.4 appearance of the plant? Some dirt, Occasional Mess X ###
###
Spotless , Neat, & Tidy ###
Impossible to see any logic or
flow sequence.
###
Most processes are apparent with
How well could a stranger walking through your
5.5 plant identify the processes and their sequence? some study. Most sequences are X
visible. ###
Processes and their sequences
are immediately visible.
###

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 ###
6.0 Suppliers Response X X
2.5+ X ###
1.6-2.4 ###
What is the average number of suppliers for
6.1 each raw material or purchased item? 1.3-1.7 ###
1.2-1.4 ###
1.0-1.1 ###
1-11 ###
12-17 ###
On average, how often, in months, are items put
6.2 up for re-sourcing? 18-23 X ###
24-36 ###
36+ ###
0% ###
What portion of raw material & purchased parts 1%-10% X ###
6.3 comes from qualified suppliers with no need for 11%-30% ###
incoming inspection? 31%-70% ###
70%-100% ###
0% ###
What portion of raw material and purchased 1%-10% X ###
6.4 items is delivered directly to the point of use 11%-30% ###
without incoming inspection or storage? 31%-70% ###
70%-100% ###
0% ###
1%-10% ###
What portion of raw materials and purchased
6.5 parts is delivered more than once per week? 11%-30% ###
31%-70% ###
70%-100% X ###
###
7.0 Setups Response X X
61+ ###
29-60 ###
What is the average overall setup time (in
7.1 minutes) for major equipment? 16-30 X ###
10-15 ###
0-9 ###
0% ###
1%-6% ###
What portion of machine operators have had
7.2 formal training in Rapid Setup techniques? 7%-18% X ###
19%-42% ###
43%-100% ###

Not at All
###
To what extent are managers and workers
7.3 measured and judged on setup performance? Informal Tracking & Review
###
Setups Tracked, Performance In
Job Description X
###

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 ###
8.0 Quality Response X X
0%-6% X ###
7%-55% ###
What portion of total employees have had basic
8.1 SPC training? 56%-80% ###
81%-93% ###
94%-100% ###
0% ###
What portion of operations are controlled with
1%-10% X ###
8.2 Statistical Process Control (SPC) 11%-30% ###
31%-70% ###
71%-100% ###
0% X ###
What portion of the SPC that is done is 1%-10% ###
8.3 accomplished by operators as opposed to 11%-30% ###
Quality or Engineering specialists? 31%-70% ###
71%-100% ###
0% ###
1%-10% X ###
8.4 What is the overall defect rate? 11%-30% ###
31%-70% ###
71%-100% ###
###
9.0 Scheduling/Control Response X X
0% X ###
What portion of work-in-process flows directly 1%-10% ###
9.1 from one operation to the next without 11%-35% ###
intermediate storage? 36%-85% ###
86%-100% ###
0% ###
What portion of work-in-process is under
1%-10% X ###
9.2 Kanban or Broadcast control 11%-35% ###
36%-85% ###
86%-100% ###
0%-50% ###
51%-70% ###
9.3 What is the on-time delivery performance? 71%-80% ###
81%-95% ###
95%-100% X ###

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 Lean Section Points and Target
Insert number here that reflects the relative
importance of the section in relation to
other sections. Total of all sections should
Section score in equal 100%
Raw point total by percent of maximum
section. possible score.

Calculates the target per

for that section based on
weight.

STRATEGIC
SECTION # OF SECTION SECTION IMPACT SECTION
SECTION POINTS QUEST AVG % FACTOR TARGET
1.0 Inventory 8 3 2.67 67% 12.0% 92.3%
2.0 Teams 18 6 3.00 75% 11.0% 84.6%
3.0 Process 12 6 2.00 50% 11.0% 84.6%
4.0 Maintenance 12 5 2.40 60% 8.0% 61.5%
5.0 Layout 11 5 2.20 55% 11.1% 85.5%
6.0 Supplier 8 5 1.60 40% 10.0% 76.9%
7.0 Setup 8 3 2.67 67% 11.1% 85.5%
8.0 Quality 4 4 1.00 25% 13.0% 100.0%
9.0 Scheduling 5 3 1.67 42% 13.0% 100.0%
SUM: 100% Sum of impact factors. This must
MAX: 13.0% equal 100%. Change impact
factor input as required.

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 ere that reflects the relative
he section in relation to
Total of all sections should

Calculates the target percentage score

for that section based on relative
weight.

mpact factors. This must

00%. Change impact
put as required.

Efforts Consulting www.effrtsconsulting.com Email:info@effortsconsulting.com Cotact: 9879391004

 Lean Profile
1.0 Inventory
100.0%
9.0 Scheduling 2.0 Teams

50.0%

8.0 Quality 3.0 Process

ACT
0.0%
UAL

7.0 Setup 4.0 Maintenance

6.0 Supplier 5.0 Layout