1. What are the Benefits? Action AKA TPM, Total Preventative Maintenance Total Productive Maintenance Breakdowns 1 Setup / adjustment 2 Idling / minor stoppages 3 Speed 4 Defects and rework 5 Start up losses 6 Equipment Six Big Losses Having no TPM on your equipment can lead to the Six Big Losses What is it? A total system of maintenance covering all major equipment. The Available Time is cut dramatically by the Six Big Loss These Losses Can be Eliminated Easily And Painlessly Total Running time of your machine is affected by : TPM is a tried and tested way to eliminate the Six Big Losses. This saves money and makes you’re factory a better places to work. It gives you, the Operator, the knowledge and confidence to manage your own machines. TPM is a long term process to increase skills, raise efficiency and achieve minimal downtime on the machine. If your Machine has no TPM then raise the issue

2. What are the Benefits? Action AKA Metrics, KPIs, Performance Management KPIs & Performance Boards Data Information Measurement Improvement How are We Performing? How are They Performing? How are You Performing? How can I Perform better? How can you improve if you don’t know where you are? To know where you are you need data! To get data, you need to measure! This data tells us whether we have improved! Highlights issues & allow us to react to them. Gives us an Indication where improvement is needed. Make the performance in all areas visible to all. Lets you see how your department is performing. What is it? To compete as a Business we must always be improving. KPIs and Performance Boards are a structured, visual approach to reviewing and improving performance. If you don’t know how you are Performing how do you know that you need to Improve? Ask!

3. What are the Benefits? Action AKA Failure Mode Effects Analysis FMEA This is the template we use to create our FMEA’s All areas must be completed to look at the possible risk for this changed Process or Product type. What is it? Introducing New Processes and Products can be risky! FMEAs identify potential Failures and their causes before they happen. Prioritises potential Failures according to their Risk Drives improvement actions to eliminate or reduce the problem from happening Provides a documented & structured way of capturing data & action If you are introducing a New Process or Product, you will benefit from carrying out an FMEA – Ask!

4. What are the Benefits? Action AKA Standard Operating Procedures, SOPs, Standard Ops 1. Select Operation 2. Record Data 3. Develop Best Method 4. Test Methods 5. Document Best Method 6. Roll Out to Team The Six Steps to Creating a Standard Operating Procedure All key processes should have a standard operation procedure. If not ask! What is it? Identifying the best way to do something leads to efficiency and business Improvement. Everyone following that same method gives us Control and Safe Working. Standard Ops define this Method of Working. Gives you a consistent way of operating Ensures you follow defined manufacturing processes A stepped approach to standardising the way we all work

5. What are the Benefits? Action AKA 80/20, Pareto This is the area the team would focus it’s efforts first! We should Act on Fact, not Opinion. Reviewing Evidence allows us to Choose What to Focus on! What is it? We want to Improve, but there’s so much to do, and limited time available. A pareto chart can show where the biggest issues are. Easy to see where the biggest problems are Will allow you to focus on the real problems Easy to use & understand Is used by all organisations With Pareto you should always target the largest portions of the chart first

6. What are the Benefits? Action AKA Nicholsons 6M, Cause & Effect, Ishikawa & Fishbone diagram Fishbone Brainstorm the Teams Ideas Organise the Teams Ideas What is it? A fishbone diagram is used to organise ideas about the potential causes of a problem. Fishbone diagrams help separate a large problem into manageable pieces. A team method is used to solve the problem. It can also help you visualize relationships between a problem and possible underlying causes. When carrying out a brainstorming session with your team always use the fishbone diagram!

7. What are the Benefits? Action AKA Plan, Do, Check, Act PDCA 1. Select Project 11. Monitor Solution 10. Implement Solution 8. Test Solutions 12. Continuous Improvement 3. Set Goals 2. Explain Reason 6. Analyse the facts 5. Gather the data 4. Prepare Action Plan 7. Develop Solutions 9. Ensure Goals are satisfied PLAN Continuous Improvement Cycle DO CHECK ACT The P.D.C.A Cycle What is it? Plan Do Check Act (PDCA) is a set of steps that provides an approach to problem solving and continuous improvement. A structured way of carrying out a project Uses a standard stepped method for completing the project Simple and easy to follow Goals for the project are always set out at the start For Projects always use the PDCA cycle!

8. What is it? Removing or minimising any function or operation that can allow any of the below to happen. What are the Benefits? Will increase time spent producing parts that our customers pay for and want in the best method possible Illustrate! There is a 8 th Waste not utilising you! ActionIf you see any of these in your area think of how you can reduce or eliminate it. AKA 7 W or 8W 7 Wastes Motion Inventory 1 1 6 6 7 7 5 5 4 4 3 3 2 2 WASTE Over-production Waiting Not Right First Time – Scrap, Rework & Defects Over-processing Transportation IN OUT

9. What is it? A easy to follow step by step approach to creating and sustaining a productive workplace What are the Benefits? Gives you the opportunity to design your work area Removes items within your area you don’t need Makes it easy to locate the tools you need to do your job Makes it easy to identify when equipment is missing Makes it easy to identify when equipment is broken Makes all of the above sustainable ActionIf your work areas is out of control you need to “5C” AKA 5 S 5 C Clearout and Classify Configure Clean and Check Conformity Custom & Practice The steps to carryout and complete a 5C activity Major clean down and classify tools based on production usage A specific place for specific items “A place for everything & everything in its place” Identify cleaning zones, establish cleaning routines involving the whole team (inc Maintenance) Consolidate the previous 3C’s, standardisation, and use of Visual Management to Control Adherence to the system rules!! and build in further improvements BeforeAfter

10. What is it? The practice of asking “WHY”, five times, why the failure has occurred in order to get to the root cause or causes of the problem. What are the Benefits? It helps to quickly determine the root cause of a problem It is easy to learn and apply ActionIf you have a problem ask “why” five times to find the real route cause of the problem. AKA Route cause analysis 5 Why WHY Q : WHY has machine stopped ? A : Overload tripped out ! 1 WHY Q : WHY overload trip ? A : Insufficient oil on shaft ! 2 WHY Q : WHY Insufficient oil ? A : Oil pump in efficient ! 3 WHY Q : WHY is pump not efficient ? A : Pump drive shaft worn ! 4 WHY Q : WHY is this shaft worn ? A : Oil filter blocked with swarf ! 5 Root-cause

11. What is it? A formal process tool for solving major problems from our customers & within the business What are the Benefits? A structured way of thinking about problems and prevention Uses a standard problem solving reporting format Fact-based and data-driven A team method is used to solve the problem ActionIf you have a major process problem ask the QA manager to raise an “8D Report” AKA 8 Decisions 8 D Before After The NST 8D format D1D2D3D4D5D6D7D8 Form a Team Define the Problem Contain the Problem Verify the Cause Verify Corrective Action Implement Corrective Action Prevent a Reoccurance Congratulate the Team

12. What is it? SPC is a tools which uses data that can tell you if you are in control of the process you are doing. What are the Benefits? It can improve product quality by controlling the process better. It can improve productivity by reducing the waste is producing spoils. It allows streamlining of the process by reducing any issues effecting the control of the process. ActionIf you think your process is out of control use SPC to determine if it is or not? AKA Statistical Process Control SPC _ Our processes needs to run inside the red lines _ _ UCL x = Xbar + 2.66 x mRbar LCL x = Xbar - 2.66 x mRbar UCL r = 3.267 x mRbar

13. What is it? Takt Time is the pace that production needed to manufacture components to meet our customer demand What are the Benefits? Essentially it provides a pace for the cell to work to. It helps our cell operations to run more effectively (in time with each operation) Gives immediate feedback on performance & issues affecting the performance. Takt Boards allow you to see what you need to produce every hour. ActionIf you have excessive time in the cell then you are not working to Takt so raise it as a issue. AKA Manufacturing drumbeat Takt Time Targets are set to what every cells can achieve efficiently &needs to achieve every hour to meet the customers demands