Forms & Activities used on ISE - type Projects Steve Snelling

List of Main Forms/Activities Project Profile & Schedule Tours Observations Time Studies Informational Interviews Plus/Minus chart Process Flow chart Cause/Effect diagram Defect locator (Measles) chart Precedence chart & Critical Path Data Analysis Pareto (80/20) chart 5-Whys diagram Facility layout drawing From/To chart Activity Relationship chart Space Utilization chart 5S Score chart Spaghetti chart (foot path/distance) Value Stream map Ergo Risk analysis chart Benchmarking FMEA (Failure Mode & Effect Analysis) chart Comparison of Alternatives Gap-to-Goal chart Simulation 2

Sample Forms Project Profile Project Schedule 3

Sample Forms Time Study Process Flow Chart Cause & Effect (Fishbone) Diagram Best Kitting Number of Kits Required Volume of Inventory Required Size of Kitting Area Number of Kitters Working Frequency of Replenishment Number of Production Areas Supported Spaghetti (foot path/distance) Chart Effect Causes 4

Facility Layout Drawing Sample Forms Value Stream Map Facility Layout Drawing 5S Score Chart Comparison Chart Simplify Sweep Standardize Sort Self Actualize 5 4 3 2 1 3 2 3 2 5

Activity Relationship Chart Sample Forms Activity Relationship Chart Precedence Diagram (and Critical Path) Shows importance of each department to other departments Digital Picture Pareto (80/20) Chart 6

Space Utilization analysis Sample Forms Gap-to-Goal Chart Space Utilization analysis CURRENT STATE FUTURE STATE GAPS Decrease incidents by 50% Incidents have been occurring Improvement Project is to be started Process: Plan View of Factory Parts Storage Aisle Packing & Shipping Machining Center Heat Treating Shows activity needed to reach a Goal Data Analysis 75% utilization of available floor space (25% free space) Defect Locator ( “measles” ) Chart Defects 7

Sample Forms From/To Chart A B C D E F Ergonomic Data FEMA Departments To Departments A B C D E F 100 ft. 200 ft. 75 ft. 25 ft. 50 ft. 35 ft. FEMA (Failure Mode & Effect Analysis) Severity x Occurrence x Detection = Risk Priority Number (RPN) Highest RPN activity is worked first Severity Occurrence Detection Least Most 10 1 2 3 4 5 6 7 8 9 Shows Travel Distance between departments Ergonomic Data Sev x Occ x Det = RPN 3 x 5 x 5 = 75 8

Sample Forms 5-Whys Diagram Plus/Minus Chart Start a New IE Project? 9 Problem Statement Why? Major Potential Cause Detailed Potential Causes Root Causes Welding failed Weld temp. was low Thermostat not set properly Mechanic not trained Mechanic could not see the temp. setting Old thermostat/ Faulty reading No documenta- tion Training not a requirement Equipment not ordered/ order new equip. Write temp. requirement Make training a requirement Not enough light Provide adequate lighting Start a New IE Project? Driving (Positive) Forces Impeding (Negative) Forces Will save money for company Helps dept. goals Meets IE goals Helps production shop Reduces flow days Improves throughput No help from shop, they are busy Low priority given Difficult to get data No guidance No sponsors of project This example shows the reasons for & against, starting a new IE project. This example looks at Why a welding failed. 9

Informational Interviews Sample Activities Tours / Observations Benchmarking Organize the tour with the process owner Get a guided tour See the surrounding areas on the tour Try to see normal conditions Ask lots of questions during the tour Take notes and debrief following the tour Understand your own area and process first Plan when to do the benchmarking within the project Plan ahead what to Benchmark Get good comparison information & data Take notes and debrief following each benchmarking activity Informational Interviews Simulation Prepare ahead who to talk to and some initial questions to ask Make sure they are experienced with the task being investigated Understand the problem from their perspective Listen for items to follow-up on later Don’t rush their answer to a complex question Take good, organized notes Understand your existing conditions before trying to build the simulation Use standard software that your company uses Build the model as simply as will meet your needs Run all options being considered through the model Document results and list all assumptions used 10