binding energy

Visual
Management &
KPI Boards
1

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 Visual evaluation of a good factory

1. Is the flow of the assembly-process visible?

(Can you find your way?)

2. Non-quality level?
- How many . Inspection?
. Testing?
. Repairs?
- Sets and sub-sets waiting beside the lines?

3. Goods flow
- Limited material on the lines
- No sub-stores

4. Transparency (=supervision)
Can one supervise the manufacturing area?
 Visual evaluation of a good factory

5. Performance-information on the line per line per workplace

Information on . Quality (short loop)
. Efficiency (output)

6. Number of indirects on the floor?

How many people “hanging-around” for
. Supervision? (why?)
. Q-problems
. Material supply

7. Contact pattern?
. Management presence on the floor?
. Open offices?
 Visual evaluation of a good factory

8. Is “production” the heart of the business?

Are support departments really supporting?

9. Housekeeping
Is the place clinically clean?

10. Working atmosphere?

Do we smell the “winning spirit” ?

11. Would you like your son or daughter to work here

in the “production” ?
 Posting company-wide
activities on the wall

1. Progress of company
 Posting company-wide
activities on the wall
2. Awards
 Posting company-wide
activities on the wall

3. Improvement activities and performance scoreboard

 Posting company-wide
activities on the wall
4. Recent presentations
 Posting company-wide
activities on the wall

5. Status of team projects

 Posting company-wide
activities on the wall

6. General information and pictures of the shop floor

Organization of a Mini-Company Meeting Area
1. Cycle Time
2. Inventory (amount, turn rate, IRA)
3. Productivity
4. Square Feet (foot print)
5. Set-up Time
6. Product Lead Time
7. People Travel
8. Product Travel
9. Volume
10. Crew Size
11. Safety/ErgonomicsLean

13
 KPIs Board for each Area
General Factory Board:
Moral
Delivery Quality Cost Productivity 6S Team
“People”

External PPM Team members

Daily Planned Daily audit Daily attendance
or Daily Productivity “names-photos-
delivery orders Daily total result with and absent.
Vs
No. of Or roles” and
complaints down time daily radar Sheet “Name
Actual “orders” Daily OEE hierarchy “Top
“Monthly” chart and status”
level”

Monthly Monthly Cost Monthly Monthly audit Overall monthly

Planned Vision-mission-
of Poor Monthly total Productivity result with absenteeism.
delivery orders values- Quality
Vs Quality down time Or Monthly “Total No.”
polices
Actual “orders” “COPQ” Monthly OEE radar chart

Analysis to Analysis to Analysis to Analysis to

Analysis to get the Analysis to get
get the root get the root get the root get the root
root cause of non the root cause of Monthly Events
cause of non cause of non cause of non cause of non
compliance non compliance
compliance compliance compliance compliance

Any reward and

Action plan to Action plan to Action plan to Action plan to
Action plan to recognition
eliminate the eliminate the eliminate the Action plan to eliminate the ceremony
eliminate the
non non non eliminate the non non
non compliance
compliance compliance compliance compliance and compliance Monthly “Value-
and
and and and Improvement and advice- lessons
Improvement learned”
Improvement Improvement Improvement Improvement

KPIs Board General Factory 14

 KPIs Board for each Area
Production:
Moral
Delivery Quality Cost Productivity 6S Team
“People”

Daily defects Daily audit Daily attendance Team members

Daily Planned Daily Productivity
“no” or Daily total result with and absent. “names-photos-
Vs Or
defected QTY down time daily radar Sheet “Name roles” and
Actual “QTY” Daily OEE
chart and status” hierarchy

Monthly Monthly Monthly Monthly audit Overall monthly

Planned defects Monthly total Productivity result with absenteeism. Team members
Vs “no” or down time Or Monthly “Total No.” Skill matrix
Actual “QTY” defected QTY Monthly OEE radar chart

Analysis to Analysis to Analysis to Analysis to

Analysis to get the Analysis to get Total no. of
get the root get the root get the root get the root
root cause of non the root cause of suggested ides per
cause of non cause of non cause of non cause of non
compliance non compliance month .
compliance compliance compliance compliance

Total no. of
Action plan to Action plan to Action plan to Action plan to
Action plan to implemented ides
eliminate the eliminate the eliminate the Action plan to eliminate the per month .
eliminate the
non non non eliminate the non non
non compliance Form for each
compliance compliance compliance compliance and compliance
and implemented idea
and and and Improvement and with its impact and
Improvement
Improvement Improvement Improvement Improvement or saving

KPIs Board Production areas 15

 KPIs Board for each Area
Maintenance:
Moral
Delivery Quality Cost Productivity 6S Team
“People”

Daily time to Daily Monthly planned Daily audit Daily attendance Team members
repair for each breakdown maintenance (No.)
result with and absent. “names-photos-
breakdown for time for all Vs.
each machine if Actual maintenance daily radar Sheet “Name roles” and
machines
exist Monthly (No) chart and status” hierarchy
MTBF for
each machine Monthly Monthly planned Monthly audit Overall monthly
Monthly maintenance (No.)
breakdown result with absenteeism. Team members
MTTR for Vs.
time for all Corrective Monthly “Total No.” Skill matrix
each machine
machines maintenance (No) radar chart

Analysis to Analysis to Analysis to Analysis to

Analysis to get the Analysis to get Total no. of
get the root get the root get the root get the root
root cause of non the root cause of suggested ides per
cause of non cause of non cause of non cause of non
compliance non compliance month .
compliance compliance compliance compliance

Total no. of
Action plan to Action plan to Action plan to Action plan to
Action plan to implemented ides
eliminate the eliminate the eliminate the Action plan to eliminate the per month .
eliminate the
non non non eliminate the non non
non compliance Form for each
compliance compliance compliance compliance and compliance
and implemented idea
and and and Improvement and with its impact and
Improvement
Improvement Improvement Improvement Improvement or saving

KPIs Board Maintenance 16

 KPIs Board for each Area
Quality:
Moral
Delivery Quality Cost Productivity 6S Team
“People”

List of Daily Daily audit Daily attendance Team members

Daily Internal Total no. of tested
open issues result with and absent. “names-photos-
Monthly PPM “rework “Units” drums per
daily radar Sheet “Name roles” and
External PPM + scrap” day.
No. of closed chart and status” hierarchy
issues “problem and or
solved per No of
month” complains Monthly audit Overall monthly
Vs. Monthly total Total no. of tested result with absenteeism. Team members
No. of open
monthly
COPQ “Units” drums per . Monthly “Total No.” Skill matrix
Issues during this
month radar chart

Analysis to Analysis to Analysis to Analysis to

Analysis to get the Analysis to get Total no. of
get the root get the root get the root get the root
root cause of non the root cause of suggested ides per
cause of non cause of non cause of non cause of non
compliance non compliance month .
compliance compliance compliance compliance

Total no. of
Action plan to Action plan to Action plan to Action plan to
Action plan to implemented ides
eliminate the eliminate the eliminate the Action plan to eliminate the per month .
eliminate the
non non non eliminate the non non
non compliance Form for each
compliance compliance compliance compliance and compliance
and implemented idea
and and and Improvement and with its impact and
Improvement
Improvement Improvement Improvement Improvement or saving

KPIs Board Quality 17

 KPIs Board for each Area
Warehouse:
Moral
Delivery Quality Cost Productivity 6S
“People”
Team

KPIs Board Safety 18

 KPIs Board for each Area
Safety:
Moral
Delivery Quality Cost Productivity 6S
“People”
Team

Daily No. of
accident inside Daily audit Daily attendance Team members
Daily total
the plan both for Daily total lost result with and absent. “names-photos-
company
paid cost due
Monthly no. hours due to injures daily radar Sheet “Name roles” and
members and to injures
of working chart and status” hierarchy
visitors
hours without
injures “even Monthly No. of Monthly audit Overall monthly
small scratch” accident inside Monthly total
the plan both for Monthly total lost result with absenteeism. Team members
paid cost
company hours due to injures Monthly “Total No.” Skill matrix
due to injures
members and radar chart
visitors

Analysis to Analysis to Analysis to Analysis to Total no. of suggested

Analysis to get the Analysis to get ides per month .
get the root get the root get the root get the root
root cause of non the root cause of
cause of non cause of non cause of non cause of non
compliance non compliance Total no. of
compliance compliance compliance compliance
implemented ides
per month .
Action plan to Action plan to Action plan to Action plan to Form for each
Action plan to
eliminate the eliminate the eliminate the Action plan to eliminate the implemented idea
eliminate the with its impact and
non non non eliminate the non non
non compliance or saving
compliance compliance compliance compliance and compliance
and
and and and Improvement and Lessons learned
Improvement
Improvement Improvement Improvement Improvement from this month

KPIs Board Safety 19

 KPIs Board for each Area
Planning:
Moral
Delivery Quality Cost Productivity 6S
“People”
Team

Daily audit Daily attendance Team members

Daily M/C result with and absent. “names-photos-
utilization daily radar Sheet “Name roles” and
Conformance Conformance Cost of losses chart and status” hierarchy
to customer to required due to long
“On Time “Quantity” as storage of
Delivery” per customer F.G. Monthly audit Overall monthly
demand Monthly total lost result with absenteeism. Team members
hours due to injures Monthly “Total No.” Skill matrix
radar chart

Analysis to Analysis to Analysis to Analysis to Total no. of suggested

Analysis to get the Analysis to get ides per month .
get the root get the root get the root get the root
root cause of non the root cause of
cause of non cause of non cause of non cause of non
compliance non compliance Total no. of
compliance compliance compliance compliance
implemented ides
per month .
Action plan to Action plan to Action plan to Action plan to Form for each
Action plan to
eliminate the eliminate the eliminate the Action plan to eliminate the implemented idea
eliminate the with its impact and
non non non eliminate the non non
non compliance or saving
compliance compliance compliance compliance and compliance
and
and and and Improvement and Lessons learned
Improvement
Improvement Improvement Improvement Improvement from this month

KPIs Board Safety 20

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KPIs Board 30