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FLV&ICSPSDeploymentDept.page 1SPSAssessmenttrainingG&I/Industrial DeploymentSchneider Production SystemSPS Assessment Training(FLV&IC)G&I/Industrial DeploymentSchFLV&ICSPSDeploymentDept.page 2SPSAssessmenttrainingIcons&meaningsExplanationCheckingpointGoodexampleBadexampleQuestionIcons&meanings Explanation FLV&ICSPSDeploymentDept.page 3SPSAssessmenttrainingIntroduction:3 Domains,10 Categories,38 LinesIntroduction:3 Domains,10 CatFLV&ICSPSDeploymentDept.page 4SPSAssessmenttrainingn1 SPS Notion1.Work instructions exist for:a.Manufacturing.b.Quality.Standardworkhasbeendefinedforeachstation2.Work instructions for Safety(based on risk analysis)are posted.(instruction board/workstation).Safetyinstructioncouldbecombinedwithotherworkinstructions,itmustbeposted(forcriticalmachines/stations)Observewhethertheoperatorrespectsthesafetyinstructionsn2 SPS Basic3.Operators were trained using the work instructionsAskthetrainershowtheyfulfillthetrainingtasksCheckwiththeoperators4.Operators understand the work instructions:a.Safety b.Quality c.ManufacturingThese3kindsofinstructionsshouldbepostedontheworkstationsAsktheoperatorswhethertheyknowthedifferentworkInstructionsdotheyunderstandthemeaningsoftheworkInstructionsPeople Commitment-SIM Production 1a-Work Instructions-P1-Q1 SPS NotionPeople CommitmenFLV&ICSPSDeploymentDept.page 5SPSAssessmenttrainingn3 SPS Standard5.Work instructions are visual Workinstructionsareeasytobeunderstood,Avoidlongsentence,withfavordrawings/chart,colorfulpicturesAcceptancecriteriasareclearlydefined.6.Workstation instructions also include maintenance information and change over information(if applicable)Twofilesareconcerned:procedureofvariantchanging&maintenancechecklist(withthetaskandfrequency)TheyshouldbepostedininstructionbookintheU-cell7.Work Instructions are respected(followed)Observethemotionoftheoperatorandcheckwiththeinstructionsn4 SPS Advanced8.There is a standard process,known by the operator,to follow when a defect is detected(may include signal device,empowerment to stop the line,call the Supervisor)DecisionmakingprocedureshouldbeavailableforoperatoratcelllevelCheckwithoperatorsPeople Commitment-SIM Production 1a-Work Instructions-P1-Q3 SPS StandardPeople CommitmFLV&ICSPSDeploymentDept.page 6SPSAssessmenttrainingnFocus on:Work Instructions available at workstation/cell/sector nKey points:5mainWorkInstructions(inorderofpriority)vSafety(forcriticalmachine/stations)vQuality,ProcessflowchartwithQualitycheckpoint.vOperations/LineDrivingvPreventiveMaintenance/Maintenance(forcriticalmachine/stations)vChangeOver&Managementinstructions(versatilitychart,5S)WhyweneedWorkInstructions?vTotrainoperatorsvTochecktheoperatorsonthemainrulestofollow,especiallySafety&QualityvTounderstandtheGlobalProcess(Flow-Chart)WorkInstructionsmustbevKnown&respectedvSimpleandVisual:canbeseenattheworkstation,avoidlongsentences,usefavordrawing,easytounderstandandacceptancecriteriasareclearlydefined.vKeepUpdatedAudit in workshopPeople Commitment-SIM Production 1a-Work Instructions-P1-Q 1-SPS Notion 2-SPS Basic 3-SPS Standard 4-SPS Advanced 5-SPS Expert1.Workinstructionsexistfor:a.Manufacturing.b.Quality2.WorkinstructionsforSafety(basedonriskanalysis)areposted.(instructionboard/workstation).4.Operatorsunderstandtheworkinstructionsa.Safetyb.Qualityc.Manufacturing8.Thereisastandardprocess,knownbytheoperator,tofollowwhenadefectisdetected(mayincludesignaldevice,empowermenttostoptheline,calltheSupervisor)5.Workinstructionsarevisual9.Operatorsareroutinelyparticipatingindeterminationofnewstandardizedworkanddefinitionofworkinstructions10.Workinstructionsare100%visual7.WorkInstructionsarerespected(followed)3.Operatorsweretrainedusingtheworkinstructions11.Workinstructionsarecontinuouslyimproved6.Workstationinstructionsalsoincludemaintenanceinformationandchangeoverinformation(ifapplicable)Focus on:Audit in workshopPeFLV&ICSPSDeploymentDept.page 7SPSAssessmenttrainingPeople Commitment-SIM Production 1a-Work Instructions-P1-Qn4 SPS Advanced(continued)9.Operators are routinely participating in determination of new standardized work and definition of work instructions OperatorsareInvolvedwhenre-thinkingthesystemandgeneratingideasforimprovementAsktheoperators:Dotheyhavesuggestionstoimprovequality,toreducethewaste?Howdotheysubmitthesuggestions?isthereaformalproceduretofollow?visual work instructionsn5 SPS Expert10.Work instructions are 100%visual11.Work instructions are continuously improved People Commitment-SIM ProducFLV&ICSPSDeploymentDept.page 8SPSAssessmenttrainingPeople Commitment-SIM Production 1b-Short interval production tracking-P3-Q 1-SPS Notion 2-SPS Basic 3-SPS Standard 4-SPS Advanced 5-SPS ExpertnFocus on:Production trackingnKey points:Quality&efficiencytrackedhourlybyoperatorParetoanalysisfordefectsandwastesisroutinelydoneandupdated(daily,weekly,monthly)“5why”isusedtoidentifytherootcauseRecurrenceofdefectsaretrackedandanalyzedActionsareefficientnKPIs:MDR-KE-IE-NEEAudit in workshop1.ProductionTracking-GoodPartsandDefectsNumbers-isimplementedpershiftbytheoperators3.Productionistrackedhourlybytheoperators(orcoherentdefinedeventcycle)5.ProductiontrackingincludesaRed-Greenbreakdownandthetop3causesofred.6.Processandcomponentdefectsaretrackedasakeyindicator.7.QualitydefectsareanalyzedandCountermeasures(containmentand/orcorrectiveaction)areconductedwithinthecurrentshift8.ComplexissuesareaddressedthroughSix-SigmaorKaizen9.Paretoanalysisofqualityissuesandwasteisroutinelydoneandupdated.10.Atleast80%ofthedifferencebetweenred/greenisexplaineddowntorootcauses.11.Correctiveactionresultsleadtoarecurrenceanalysisofdefects(defecttypesaretrackedandrecordedinalogfile)4.Atthebeginningofeachshift,thereisareviewwithoperatorsofissuesandobjectivesrelatedto:a)production;b)quality;andc)barriers2OperatorsareawareofcurrentandpotentialprocessandcomponentqualitydefectsrelatedtoeachproductrangePeople Commitment-SIM ProducFLV&ICSPSDeploymentDept.page 9SPSAssessmenttrainingn1 SPS Notion1.Production Tracking-Good Parts and Defects Numbers-is implemented per shift by the operators Productiontracking(includequantityandquality)donebyoperatorpershiftCheckatcelllevel2.Operators are aware of current and potential process and component quality defects related to each product range OperatorsareawareofqualitydefectsrelatedtoeachproductrangeDefectsarelistedbyQC(ex.Differentcodemeansdifferentdefects)Checkwithoperatorsn2 SPS Basic3.Production is tracked hourly by the operators(or coherent defined event cycle)Productiontracking(includequantityandquality)donebyoperatorhourlyIfTT0.5H,theintervaloperatorrecordedshouldequaltoTTChecktheSIMsheetatcelllevel4.At the beginning of each shift,there is a review with operators of issues and objectives related to:a)production;b)quality;and c)barriers Observeintheworkshoptocheck:Isthereameetingwithoperatorsatthebeginningofshift?Whatkindoftopicsreviewedinthismeeting?People Commitment-SIM Production 1b-Short interval production tracking-P3-Q1 SPS NotionPeople CommitmenFLV&ICSPSDeploymentDept.page 10SPSAssessmenttrainingPeople Commitment-SIM Production 1b-Short interval production tracking-P3-Qn3 SPS Standard5.Production tracking includes a Red-Green breakdown and the top 3 causes of red.Red-GreenbreakdownshoulddoneaccordingtoSPSTop3causesofredshouldbeanalyzeddaily6.Process and component defects are tracked as a key indicatorFortheprocessdefects,ittrackedasFirstPassRatio,etc.Fornonqualitypart,Scrap,itscalculatedinNQC.CheckwithlineleaderandQCengineer.7.Quality defects are analyzed and Countermeasures(containment and/or corrective action)are conducted within the current shiftInformationontheQualityissueincludesthefollowingitems:whathashappened/whatistherootcause/whatisthecountermeasure-containmentand/orcorrectiveaction-/whoisresponsible/whenTheanalysismustbebasedoncomparison-goodpart/badpart,operator1/operator2,day1/day2,.-andfactsActioneffectivenessisverifiedbythelineleader/supervisorCheckwiththelineleader/supervisorRed/Green breakdown according to SPSPeople Commitment-SIM ProducFLV&ICSPSDeploymentDept.page 11SPSAssessmenttrainingPeople Commitment-SIM Production 1b-Short interval production tracking-P3-Qn4 SPS Advanced 8.Complex issues are addressed through Six-Sigma or KaizenSix-SigmaisfocusonreducingvariabilitytoreachaperformanceonaprocessKaizenisfocusoneliminatingwasteonthewholeproductflow9.Pareto analysis of quality issues and waste is routinely done and updated Paretoanalysisofqualityissuesandwastedoneandupdatedatleastdoneweekly10.At least 80%of the difference between red/green is explained down to root causesUse“5why”tofindtherootcausesPeople Commitment-SIM ProducFLV&ICSPSDeploymentDept.page 12SPSAssessmenttrainingPeople Commitment-SIM Production 1b-Short interval production tracking-P3-Qn5 SPS Expert11.Corrective action results lead to an recurrence analysis of defects(defect types are tracked and recorded in a log file)Defectsandnonconformitiesaretrackedandrecordedbydefecttypeinalogfile.Thisistheonlywaytomakesurethehavebeeneradicatedbythecorrectiveactions.ThislogfilemustbedisplayedontheinformationboardoftheproductioncellRecurrence of defect 2!People Commitment-SIM ProducFLV&ICSPSDeploymentDept.page 13SPSAssessmenttrainingPeople Commitment-SIM Production 1c-SIM Production implementation-P4,P10 1-SPS Notion 2-SPS Basic 3-SPS Standard 4-SPS Advanced 5-SPS ExpertnFocus on:SIM Production implemented and respected the plant event cycle.nKey points:OperatorsareinvolvedinSIMProduction(beginning/endofshift)vObjectivesDefinitionvResults/BarrierLog&SuggestionsystemmanagementvSafety&5SManagementSupportfunctionsareinvolvedinSIMProductionvResultsAnalysis/IndicatorsReviewvBarrierLogManagementvActionPlanManagement/EscalationsystemAudit in workshopAttend the daily SIM meeting1.SIMProductionconcepts(SPSModel)arepartiallyimplemented2.PlantEventCycle(frequency,contributors,deliverables)isknownbyeveryoneinproduction3.SIMProductionisled(requiredbyandparticipatedin)bythePlantManager4.Cell/ProductSectorshortintervalcyclesandfrequencyarerespectedaccordingtoSPS5.Themanagerandhisteamrespectthefrequencyanddurationoftheeventcycle6.Supportfunctionsmembers(Methods,Materials,Logistics,Maintenance,Quality,Engineering)participateinSIMProductionmeetings7.InternalKPIsparticulartotheproductorprocesshavebeenestablishedandaretracked.8.Theshiftsupervisormanagestheactionplansandpoststhem9.Evidenceofdynamicmanagementoftheactionplans:a)followedup,b)ontime,c)evidenceofsuccess.10.HumanresourcesfacilitateandAssesstheSIMProduction11.EachmanufacturingsectorconsistentlyreachonesKPIsobjectives.12.InternalKPIsshowsustainedimprovementovera12monthsperiodnKPIs:Output:Realized-ForecastedSafety+5SQuality:ServiceLevel-MDREfficiency:KE/IENEE/OEEBarrierLog+ActionPlanPeople Commitment-SIM ProducFLV&ICSPSDeploymentDept.page 14SPSAssessmenttrainingPeople Commitment-SIM Production 1c-SIM Production implementation-P4,P10 n1 SPS Notion1.SIM Production concepts(SPS Model)are partially implementedThereareregularSIMmeetingsinproductionCheckwithoperators,lineleaders,productionmanager2.Plant Event Cycle(frequency,contributors,deliverables)is known by everyone in production Planteventcycleareestablishedincludefrequency,contributors,deliverablesSPS SIM event CyclesPeople Commitment-SIM ProducFLV&ICSPSDeploymentDept.page 15SPSAssessmenttrainingn2 SPS Basic3.SIM Production is led(required by and participated in)by the Plant Manager Askplantmanagerwhetherheknowtheplanteventcycle,doeshe/sheattendtheSIMdailymeeting(onceperweek)Checkwithproductionmanager4.Cell/Product Sector short interval cycles and frequency are respected according to SPSThereareshiftly,daily,weeklymeetingaccordingtoSPSCheckwithoperators,lineleaders/supervisors,productionmanager5.The manager and his team respect the frequency and duration of the event cycle SIMmeetingatfixedtimewiththefixeddurationCheckwithlineleaders/supervisors,andobservethedailymeeting.n3 SPS Standard6.Support function s members(Methods,Materials,Logistics,Maintenance,Quality,Engineering)participate in SIM Production meetingsObservethedailymeetingandcheckwiththeparticipates.7.Internal KPIs particular to the product or process have been established and are trackedKPIsincludeoutput,safety,5S,OTDM,MDR,KE/IE,NEE/OEE,shouldbereviewedinthedailySIMmeetingObservethedailymeetingtocheckwhethertheKPIsbetrackedPeople Commitment-SIM Production 1c-SIM Production implementation-P4,P10 2 SPS BasicPeople CommitmentFLV&ICSPSDeploymentDept.page 16SPSAssessmenttrainingPeople Commitment-SIM Production 1c-SIM Production implementation-P4,P10 n4 SPS Advanced 8.The shift supervisor manages the action plans and posts themActionplansshouldbefollowedandpostedontheSIMboard.9.Evidence of dynamic management of the action plans:a)followed up,b)on time,c)evidence of successChecktheactionfollow-upfiletoseetheevidence10.Human resources facilitate and Assess the SIM Production HRneedtobeinvolvedinSIMproduction,Attendthedailymeetingfrequently,Organizeregularaudit,n5 SPS Expert11.Each manufacturing sector consistently reach ones KPIs objectivesCheckKPIs(output,safety,5S,OTDM,MDR,KE/IE,NEE/OEE)reporttoseetheresult12.Internal KPIs show sustained improvement over a 12 months periodCheckthe12monthstrendPeople Commitment-SIM ProducFLV&ICSPSDeploymentDept.page 17SPSAssessmenttrainingPeople Commitment-SIM Support Functions2a-SIM support functions-P5,P10 1-SPS Notion 2-SPS Basic 3-SPS Standard 4-SPS Advanced 5-SPS ExpertnFocus on:SIM support function implemented and respected the plant event cycle.Audit in 2-3 support function1.SIMProductionconcepts(SPSModel)arepartiallyimplemented2.PlantEventCycle(frequency,contributors,deliverables)isknownbyeveryoneinproduction3.SIMProductionisled(requiredbyandparticipatedin)bythePlantManager4.Cell/ProductSectorshortintervalcyclesandfrequencyarerespectedaccordingtoSPS5.Themanagerandhisteamrespectthefrequencyanddurationoftheeventcycle6.Supportfunctionsmembers(Methods,Materials,Logistics,Maintenance,Quality,Engineering)participateinSIMProductionmeetings7.InternalKPIsparticulartotheproductorprocesshavebeenestablishedandaretracked.8.Theshiftsupervisormanagestheactionplansandpoststhem9.Evidenceofdynamicmanagementoftheactionplans:a)followedup,b)ontime,c)evidenceofsuccess.10.HumanresourcesfacilitateandAssesstheSIMProduction11.EachmanufacturingsectorconsistentlyreachonesKPIsobjectives.12.InternalKPIsshowsustainedimprovementovera12monthsperiodnKPIs:%Tasksdone/Tasksplanned%TasksintimeDiary with red/greennKey points:EventcyclearedefinedandrespectedTheremustbeaindividualmeetingbetweenmanagerandhisstaff(1to1)DiaryisusedtomanageworkloadvWorkloadisplanedandmeasuredvWorkloadisanalyzed:red/green,realized/forecastedSupportFunctionsarefocusedonProduction&CostumerServicevGlobalActionPlanisdefined,BarrierLogisupdatedinSIMvPrioritiesaredefinedandareconsistentintheagendaofallsupportfunctionsPeople Commitment-SIM SupporFLV&ICSPSDeploymentDept.page 18SPSAssessmenttrainingPeople Commitment-SIM Support Functions2a-SIM support functions-P5,P10n1 SPS Notion1.SIM Support Function concepts(SPS Model)are known PlantmanagementteamreceivedtheSIMtraining2.Plant Event Cycle (frequency,contributors,deliverables)is known by all support functions Planteventcycleareestablishedincludefrequency,contributors,deliverables.Checkwithsomesectormanagerandstaffsn2 SPS Basic3.SIM Support Functions is led(required and participated in)by the plant Manager Askplantmanagerwhetherheknowtheplanteventcycle,Aretherescheduled1to1meetingbetweenplantmangerandfunctionmanagersweeklyIsthereaweeklycoordinationmeetingwithallsupportmanagerCheckwithfunctionmanagers4.The manager and his team respect the frequency and duration of the event cycle SIMmeetingholdatfixedtime,withfixeddurationCheckwithsupportengineers5.The manager organizes a weekly contact with his staff(1 to 1)Thereisaweekly1to1meetingbetweenfunctionmanagerandhisstaffstoreviewactionplan,workload,priorityCheckwithstaffsPeople Commitment-SIM SupporFLV&ICSPSDeploymentDept.page 19SPSAssessmenttrainingPeople Commitment-SIM Support Functions2a-SIM support functions-P5,P10n3 SPS Standard6.Staff individuals diary is used as a scheduling toolCheckseveralindividualdiariestoseethesituation7.A global product-process action plan is available and updated Checktheactionfollow-upfile(atplantlevel)toseewhetheritisreviewedandupdated8.SIM SPS model is fully implementedFunctioneventcycleexitandrespectSPSTheres1to1meetingbetweenmanagerandhisdirectreportsDiariesareusedtomanageworkloadSupportfunctionarefocusedonproduction&costumerserviceSPS SIM event CyclesPeople Commitment-SIM SupporFLV&ICSPSDeploymentDept.page 20SPSAssessmenttrainingPeople Commitment-SIM Support Functions2a-SIM support functions-P5,P104 SPS Advanced 9.Diary planning intervals are 2 hours blocksCheckseveralindividualdiariestoseetheinterval10.Tasks planned in the diaries according to the Pareto Analysis of issues/barriers identified production Tasks&ActionplanscomefromParetoAnalysisofissues/barriers inproductionSIMCheckstaffdiariesofsupportfunctionwiththeactionfollow-upfileonproductionSIMboardtowhethertheyarematched11.Human resources facilitate and Assess the SIM Support FunctionsHRmustfacilitateandassessthesupportfunctionSIM,tosetupKPIsforallfunctionDept,tomeasurestaffworkload,toorganizeregularreview/audit,n5 SPS Expert12.Manufacturing KPIs are in continuous improvement CheckKPIsreporttoseetheresultPeople Commitment-SIM SupporFLV&ICSPSDeploymentDept.page 21SPSAssessmenttrainingPeople Commitment-SIM Support Functions2b-SIM Support functions Efficiency-P6 1-SPS Notion 2-SPS Basic 3-SPS Standard 4-SPS Advanced 5-SPS ExpertnFocus on:Staff workload management&support function efficiency.nKey points:Prioritiesareknownbyeachstaffmember-bothfactoryprioritiesandpersonalprioritiesPrioritiesaretakenintoaccountandevidenceexistsinthe“to-do”listsanddiariesResourcesareadapted:resourcesareappliedtothehighestpriorityactivitiesActivitiesoractions:doestheplantverifyandfollow-upthattheresultsaresustained?nKPIs:%Tasksdone/Tasksplanned%TasksintimeAudit 2-3 support function1.Globalteamworkloadisassessed.(eg:AnnualHumanResourceRevieworBusinessPlanCycle)2.Individualworkloadisassessed(todolist)3.SupportFunctionscoreskillsaredefinedandformalized(updatedonceayear)4.Numberoftaskscarriedoutperpersonperweekisscheduledandtracked(RatioImplemented/Scheduled)5.Workloadandresourcesarewellbalancedaccordingtotheobjectives6.SupportfunctionshavedefinedtheirownKPIs;theyaretracked&analyzed7.SupportFunctionKPIsareincontinuousimprovementPeople Commitment-SIM SupporFLV&ICSPSDeploymentDept.page 22SPSAssessmenttrainingPeople Commitment-SIM Support Functions2b-SIM Support functions Efficiency-P6n1 SPS Notion1.Global team workload is assessed.(eg:Annual Human Resource Review or Business Plan Cycle)ThisglobalworkloadassessmentisthebaseofDeptheadcountrequirement,Itshouldbereviewedonceayearorbaseonbusinessplancycle.CheckwiththeDeptmanagern2 SPS Basic2.Individual workload is assessed(to do list)Usethesometoolstoassesstheindividualworkload(e.g.to-do-list).Thecontentsofthefileshouldincludeworkload,priorities,duedate,planedratioCheckwithdept.managerandstaff3.Support Functions core skills are defined and formalized(reviewed once a year)Makethered/greenactivitiesselfanalysisforeachnon-DVCemployeeMakeacompetency(skills&knowledge)assessmentforeachemployeeClearlydefinetheJDforeachstaff,andtheJDshouldbereviewedonceayear.Checkwithdept.managerandstaffPeople Commitment-SIM SupporFLV&ICSPSDeploymentDept.page 23SPSAssessmenttrainingPeople Commitment-SIM Support Functions2b-SIM Support functions Efficiency-P6n3 SPS Standard4.Number of tasks carried out per person per week is scheduled and tracked(Ratio Implemented/Scheduled)Auditseveralindividualdotolistanddiary.Checktheratioofimplemented/scheduled5.Workload and resources are well balanced according to the objectivesMeasureandbalancetheindividualworkloadResourceareappliedtothehighpriorityactivitiesaccordingtotheobjectivesn4 SPS Advanced 6.Support functions have defined their own KPIs;they are tracked&analyzedKPIsclearlydefinedforeachdepartment,KPIsshouldbetracked,an
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