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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
1.1 middle and upper managers can state from memory the 56%-80%
current 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
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+

2.0 The Team Approach Response X


Exploitive
Bureaucratic
2.1 What is the organization type? Consultive
Participative
Highly Participative
Individual Incentive
Hourly Wage
How are workers on the factory floor
2.2 compensated? Group Incentive
Salary
Salary+Annual Bonus
Transfers & Layoffs Every
Retraining Year
Reduce
2.3 To what extent do people have job security? Layoffs
Layoffs Are Rare
31%+
14%-30%
2.4 What is the annual personnel turnover 7%-11%
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%
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%
91%-100%
3.0 Processes Response X
4+
How many large-scale machines or single- 3
3.1 process areas are in the plant through which 2
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 selction with respect to scale? Medium/Mixed
Small Scale
Very Difficult
How easy is it to shift output when the product
3.3 mix changes? Moderately Difficult
Easy
Very Difficult
How easy is it to alter the total production rate
3.4 by +/-15%? Moderately Difficult
Easy
96%-100%
What is management's target operating 91%-95%
3.5 capacity for individual departments or 86%-90%
machines? 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
technology level? Simple Technologies

4.0 Maintenance Response X


Describe equipment records and data. Include Non-Existent
4.1 records of uptime, repair history, and spare Substantially Complete
parts. Include repair and parts manuals. Complete & Accurate
71%-90%
Excluding new installations and construction 51%-70%
projects, what percentage of maintenance
4.2 hours is unplanned, unexpected, or
26%-50%
11%-25%
emergency?
0%-10%
No PM
1%-10% Coverage
Does maintenance have and follow a defined
4.3 preventive schedule? 11%-30% Coverage
31%-90% Coverage
91%+ Coverage
Often
Do equipment breakdowns limit or interrupt
4.4 production? Occasionally
Frequently
Unknown
0%-75%
What is the overall average availability of plant
4.5 equipment? 76%-90%
91%-95%
96%-100%
5.0 Layout & Handling Response X
71%-100%
46%70%
What portion of total space is used for storage
5.1 and material handling? 30%-45%
16%-30%
0%-15%
71%-100%
46%70%
What portion of the plant space is organized by
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


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

Spotless , Neat, & Tidy

Impossible to see any logic or


flow sequence.

How well could a stranger walking through your Most processes are apparent
5.5 plant identify the processes and their with some study. Most
sequence? sequences are visible.

Processes and their sequences


are immediately visible.
6.0 Suppliers Response X
2.5+
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
6.2 put up for re-sourcing? 18-23
24-36
36+
0%
What portion of raw material & purchased parts 1%-10%
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%
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%

7.0 Setups Response X


61+
29-60
What is the average overall setup time (in
7.1 minutes) for major equipment? 16-30
10-15
0-9
0%
1%-6%
What portion of machine operators have had
7.2 formal training in Rapid Setup techniques? 7%-18%
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
8.0 Quality Response X
0%-6%
7%-55%
What portion of total employees have had basic
8.1 SPC training? 56%-80%
81%-93%
94%-100%
0%
1%-10%
What portion of operations are controlled with
8.2 Statistical Process Control (SPC) 11%-30%
31%-70%
71%-100%
0%
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%
8.4 What is the overall defect rate? 11%-30%
31%-70%
71%-100%

9.0 Scheduling/Control Response X


0%
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%
1%-10%
What portion of work-in-process is under
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%
For each question, place an "X"
in box next to the most
appropriate answer. If the
information is unavailable, use
the topmost box of that
question for your answer.
Insert number here that reflects the
relative importance of the section in
relation to other sections. Total of all
Section score in sections should equal 100%
Raw point total percent of maximum
by section. possible score.
Calculates the target p
score for that section b
relative weight.

STRATEGIC
SECTION # OF SECTION SECTION IMPACT SECTION
SECTION POINTS QUEST AVG % FACTOR TARGET
1.0 Inventory 0 3 0.00 0% 12.0% 92.3%
2.0 Teams 0 6 0.00 0% 11.0% 84.6%
3.0 Process 0 6 0.00 0% 11.0% 84.6%
4.0 Maintenance 0 5 0.00 0% 8.0% 61.5%
5.0 Layout 0 5 0.00 0% 11.1% 85.5%
6.0 Supplier 0 5 0.00 0% 10.0% 76.9%
7.0 Setup 0 3 0.00 0% 11.1% 85.5%
8.0 Quality 0 4 0.00 0% 13.0% 100.0%
9.0 Scheduling 0 3 0.00 0% 13.0% 100.0%
SUM: 100%
MAX: 13.0%
Sum of impact factors. This must
equal 100%. Change impact
factor input as required.
here that reflects the
tance of the section in
er sections. Total of all
d equal 100%

Calculates the target percentage


score for that section based on
relative weight.

mpact factors. This must


%. Change impact
ut as required.
Lean Profile

1.0 Inventory

2.0 Teams 100.0%

9.0 Scheduling

3.0 Process 8.0 Quality Column G


Column E
0.0%

4.0 Maintenance 7.0 Setup

5.0 Layout 6.0 Supplier


olumn G
olumn E