PROPOSED VISUAL DISPLAY BOARD AND SHIFT HAND-OVER MEETING

01 March 2008

Proposed PF Visual Display Board & Shift Hand-over Meeting

Significance:

Communication gaps can result to production downtime/delays. Communication gaps can lead to serious mistakes. Communication is becoming more critical as we move into multi-product manufacturing.

Proposed PF Visual Display Board & Shift Hand-over Meeting

AS IS:

Two shift hand-over. One between out-going and in-coming shift leads. Another one between outgoing and in-coming supervisor or Lead Tech. Very little participation from the technicians. No participation from Maintenance Technician. Team members knows very little of what is happening in other modules. Weak team engagement. Very distracting. Too many interference.
(radio & phone calls, late comers).

Proposed Visual Display Board & Shift Hand-over Meeting

TO BE:

To have a single shift hand-over meeting. To centralize the display board to provide a one stop overview of the plant daily shift performance. To use the display board as a tool for shift handover meeting. To create ownership/accountability of metrics. To improve the hand-over of information (ie. work instructions, learning's, other communication.) To improve team engagement.

TO BE:

PF-1 VISUAL DISPLAY BOARD

Guidelines Safety Quality Supply / Productivity Report Team Engagement

Meeting Agenda Shift Lead

Safety Daily report Shift Lead

Quality Event / Atypical daily report Shift Lead

Dispensing Shift Output Technician

TCM-710 Compression Shift Output Technician

Kaizen Submission All

Work Instructions / Communication Shift Lead

Safety talk
Shift Lead

Meeting Dos & Don'ts Shift Lead

Safety Incident report Shift Lead

cGMP / GDP daily report Shift Lead

Charging Shift Output Technician

TCM-720 Compression Shift Output Technician

Work Assignment Shift Lead

Work cGMP / GDP Instructions / talk Communication Shift Lead

Shift Lead

Other Metrics
Shift Lead

RFT report
Shift Lead

HSM Shift Output

Technician

TCM-730 Compression Shift Output Technician

Shift Attendance
Shift Lead

Work Instructions / Communication Shift Lead

5 S talk Shift Lead

3 ROWS DESIGN. USING A4 SIZE PAPER

TO BE: SHIFT HAND-OVER MEETING AGENDA:

Safety Shift Lead Safety daily report (traffic light) Incident/Accident report (brief) Quality Shift Lead Event / Atypical Report. 5 Why? Productivity Technician Production output (qty, yield). Downtime hours. Why? Work order status. On schedule or behind schedule, how many days? Team Engagement Shift Lead Kaizen submission by technician Work instruction / communication Safety talk cGMP / GDP talk 5 S talk

TO BE: SHIFT HAND-OVER MEETING AGENDA:

Required to attend from out-going shift Shift Lead Shift Supervisor 1 Technician from each module Maintenance Technician Required to attend from in-coming shift All. Including Maintenance Technician. Except technicians assigned to take-over the module Hand-over procedure - 1 to 1 (To take place at the module) Step 1 - The in-coming shift lead shall assign a technician to take-over the modules that cannot stop operation. A 1 to 1 hand-over shall take place at the module. Step 2 - Module out-put, issues encountered shall be discussed in brief. MPD and clean & usage log shall be checked by the in-coming technician for completeness. This action would help drive the reduction of GDP errors.

TO BE: SHIFT HAND-OVER MEETING AGENDA:

Hand-over procedure Group (To take place at the Visual Board) Step 1 The out-going Shift Lead shall report the safety performance. To discuss in brief any incident report. Step 2 The out-going shift Lead shall report the quality performance. To discuss in brief any event or atypical. Step 3 The out-going shift technician (designated for each module) shall report the production performance. To explain brief why target is not met & any issue. Step 4 The out-going shift lead shall report any new instructions/communications. Step 5 The out-going shift can leave. Step 6 The in-coming shift lead shall continue with the meeting to discuss the days work assignment, safety talk, cGMP talk and 5 S talk & any CI suggestions. Step 7 - End the meeting.

TO BE: SHIFT HAND-OVER GROUD RULES:

Meeting Ground Rules
1. Be on-time.

Responsibility
All Out-going shift All All All All

2. Update the visual display board before meeting starts. 3. Provide full attention. One meeting policy.
4. Switch-off walkie talkie.

5. Speak clearly.
6. Lengthy discussion shall be placed on a parking lot.

Meeting Timing: Morning - 7:30am to 7:45am Night - 7:30pm to 7:45pm

Meeting Venue: Visual Display Board

SAFETY REPORTING

Safety Traffic Light Daily Reporting

Date
01 March
02 March

Team
A B C D

Status

Remarks

IBC lid drop-out. Walkie stacker hit the wall.

RED YELLOW GREEN

ACCIDENT / LOST TIME INCIDENT or NEAR MISS NO ISSUE

QUALITY REPORTING

Quality Daily Reporting

Event / Atypical Daily Reporting
Date
01 March 08 02 March 08

Team
A B C D

# of Event/Atypical Raised
2 1 0 1

To report in brief any event or atypical

GMP / GDP Traffic Light Daily Reporting

Date
01 March
02 March

Reported by
Tan Peter John Robert

Status

Remarks

IBC # 007 - Missing entry on the clean & usage log . MPD - Section C, over-writing.

To be checked & reported by out-going shift. 1. 2. MPD check for previous shift. Clean & usage log check for previous shift

RED YELLOW GREEN

cGMP / GDP NON-CONFORMANCE NEEDS IMPROVEMENT NO ISSUE

PRODUCTIVITY REPORTING

Productivity Reporting

USE EXISTING FORMS

To add a shift target for compression. Example: TCM 710 = 10 drums per shift TCM 720 = 15drums per shift. Or Strength, 10/10 = 10 drums per shift Strength, 10/20 = 15 drums per shift

TEAM ENGAGEMENT REPORTING

Team Engagement Reporting

Kaizen submission tracking TEAM D
Jan Feb March April May

Submitted
NO NAME

Implemented

Submitted

Implemented

Submitted

Implemented

Submitted

Implemented

Submitted

Implemented

1 2 3 4 5 6 7 8 9 10 11 12

Azman Husin Niranjan Kumar Chen Yu Min, Richard Hou Fang Tao, Hoft Ooi Kim Seong Lim Hwee Kiang Yusainie Bin Rahmat Lee Teck Hock Angelo Udayan Heng Wei Jie Rajesh Umakanthan

IIII

II

Total number of suggestions is to be use as a performance appraisal target.

Team Engagement Reporting

Period: 11 April - 27April Dispensing & Charging High Shear Module Compression Others

Chen Y M (Lead) Lim W K Rajesh

LEE (Lead) Udayan Heng W J Azman (Mentor)

Kumar (Lead) Ooi Hoft Yus

Azman
(Compression leaning/Other assignment to swap with Kumar or Ooi)

Period: 30 April - 15 May Dispensing & Charging High Shear Module Compression Others

LEE (Lead) Udayan Heng W J

Chen Y M (Lead) Lim W K Rajesh Pairin (Mentor)

Kumar (Lead) Ooi Hoft Yus

Azman
(Compression leaning/Other assignment to swap with Kumar or Ooi)

Team Engagement Reporting

Safety, GMP & 5 S Talk

A THEME based communication. Example: Safety Basic PPE GMP Rule # 1. 5 S Sort

The THEME shall remain the same for 1 week and change every week. This would help drive awareness and behavior change

VIDEO

TO BE:

PF-1 VISUAL DISPLAY BOARD

Guidelines Safety Quality Supply / Productivity Report Team Engagement

Meeting Agenda
Shift Lead

Safety Daily report

Shift Lead

Quality Event / Atypical daily report

Shift Lead

Dispensing Shift Output

Technician

TCM-710 Compression Shift Output

Technician

Kaizen Submission
All

Safety talk
Shift Lead

Meeting Dos & Don'ts

Shift Lead

Safety Incident report

Shift Lead

cGMP / GDP daily report

Shift Lead

Charging Shift Output

Technician

TCM-720 Compression Shift Output

Technician

Work Instructions / Communication

cGMP / GDP talk

Shift Lead

Other Metrics
Shift Lead

RFT report
Shift Lead

HSM Shift Output

Technician

TCM-730 Compression Shift Output

Technician

Shift Attendance

5 S talk
Shift Lead

3 ROWS DESIGN. USING A4 SIZE PAPER