1. Consulting Business Start-up Evaluation Progress Report #1 EMMP Capstone Project Central Team 12-21-02

2. Agenda: Initial Work Completed Project Tools Created Project Activities To Date Attention Areas Summary Next Steps

3. 12-21-02 Project Definition: Evaluate the start up of an engineering consulting business focusing on manufacturing improvements. Deliverables include case study, business start-up analysis and validation study Limited to 1,200 team work hours Limited to $100 in expenses Initial Work Completed: (Initial Project Proposal)

4. 12-21-02 Project Definition: Evaluate the start up of an engineering consulting business focusing on manufacturing improvements. Change Notice 1 – Redefine the organization structure from Functional to Matrix. Change Notice 2 - Deliverables include case study and business start-up analysis (modify validation study) Change Notice 2 - Limited to 700 team work hours (initial scope reduced from 1,200) Limited to $100 in expenses Initial Work Completed: (Current Project Proposal)

5. 12-21-02 Due to Change Notice 2 (reduce hours, modify validation study), major schedule revisions have occurred New schedule has been created to reflect these changes: Initial Work Completed: (Schedule)

6. 12-21-02 Project Control Tools Created: Project Hours Spreadsheet Master Revision Control Tracker (MRCT) Change Notice Process Schedule Update Process

7. 12-21-02 Project Control Tools Created: Project Hours Spreadsheet –Document created to track overall project time.

8. 12-21-02 Project Control Tools Created: Project Hours Spreadsheet –Process After each task, team is responsible for communicating logged hours. –Process Owner Jim Heimler is maintaining this log.

9. 12-21-02 Project Control Tools Created: Project Hours Spreadsheet –Current Status Task #Task NameDuration Task Running TotalsStartFinish 26Case Study75.56 days011/6/02 8:002/19/03 13:30 27Brainstorm5 days011/6/02 8:0011/12/02 17:00 28Brainstorm Methodologies2015.511/6/02 8:0011/8/02 16:00 29Determine Methodologies for Review5511/8/02 16:0011/9/02 16:00 30Teleconference #15511/12/02 12:0011/12/02 17:00 31Assign Methodologies for in Depth Study2.51.2511/9/02 16:0011/12/02 13:30 32Research Criteria and Research Activities28 days011/12/02 13:3012/20/02 13:30 33Establish deliverables (criteria) for methodologies study157.2511/12/02 13:3011/15/02 13:30 34Research Methodologies per establish criteria706311/15/02 13:3012/12/02 13:30 35Write Report for each Methodology152012/12/02 13:3012/17/02 13:30 36Present Individuals findings on each Methodology51512/17/02 13:3012/19/02 13:30 37Compile Team Reports10 hrs12/19/02 13:3012/20/02 13:30 38Develop Continuous Improvement Methodology43 days012/20/02 13:302/19/03 13:30 39Analyze each methodology and determine best practices5 hrs012/20/02 13:3012/21/02 13:30 40Compile best practices and formulate our own CIM50 hrs012/21/02 13:301/18/03 13:30 41Determine the most appropriate communication method10 hrs01/18/03 13:301/22/03 13:30 42Complete final Case Study document100 hrs01/22/03 13:302/19/03 13:30 43Case Study Approval0 hrs02/19/03 13:30 TOTALS 137.5132 DIFFERENCE 5.5Positive Variance * Does not include Administrative Time *

10. 12-21-02 Project Control Tools Created: Master Revision Control Tracker (MRCT) –Source of the current status of project documents –Revision control log

11. 12-21-02 Project Control Tools Created: Master Revision Control Tracker (MRCT) –Process: –Maintained by one person Process owner: Tron Melzl

12. 12-21-02 Change Notice Process –If an aspect of the project requires a major change is scope, quality or timing, a process has been put in place to address the concern. –First all team members need to discuss and approve. –Submit per our Communication Plan Matrix. Project Control Tools Created:

13. 12-21-02 Change Control Form (CCF) Requestor Information Revision to master proposal Need Approval Potential Impact of Request Governing Body Project Sponsor Potentially Affected Stakeholders Change from 1200 total team hours to 700 total team hours. Scope determined too large. Looked at available resources and required resources for project and found significant mismatch. While targeting 700 total hours, the Validation study was dropped from the scope and the Business Case study was amended to reduce total hours. A Validation Plan will be added. Description (What and Why) 11/5/02 Request Date Central Team Requestor UWM EMMP - CENTRAL CAPSTONE PROJECT Project Name Project Control Tools Created:

14. 12-21-02 Project Manager Information Affected Stakeholder comments Resources more in line with reality. Assessment (scope, timing, budget, resources, other) Proposal must change and be re approved Schedule must change to reflect new work load. Impact Assessment performed by: 002 Change Request Number DateDenied Approved Governing Body (if required) Project Sponsor Central Team Project Manager Follow Up Action Lessons Learned Impact From Action Above Project Control Tools Created:

15. 12-21-02 Change Notice Process –Process Owner Team unanimously agrees to change and Tony Sciortino writes and submits paperwork for approval. –Current Status CN001 Approved –Update proposal on organizational structure. CN002 Approved –Revise plan to 700 total hours (modify Validation Study) Project Control Tools Created:

16. 12-21-02 Schedule –Based on time sheets, task hours are recorded when complete in baseline schedule. –Actual completion dates are also recorded. –These two data points measure team effectiveness. Project Control Tools Created:

17. 12-21-02 Schedule –Process Owner Team to turn in data and Tony Sciortino to report out to team and others status to plan. Team to determine and execute any actions if required. Project Control Tools Created:

18. 12-21-02 Schedule –Current Status Project Control Tools Created:

19. 12-21-02 Budget –A $100 budget was set up at the beginning of the project for incidentals. –No budget forecast. –No spending to date. Project Control Tools Created:

20. 12-21-02 Project Activities To Date: Choosing Research Methodologies –Compiled industry continuous improvement methodologies. Broken down into description, steps, tools, etc. –Choose methodologies applicable to our business environments and interests.

21. 12-21-02 Project Activities To Date: Choosing Research Methodologies Six Sigma Lean Manufacturing Quick Response Manufacturing (QRM) Demand Flow Technology (DFT) Focus PDCA Model Total Quality Management (TQM) Quality Education System PACE Theory of Inventive Problem Solving (TRIZ) Achieving Competitive Excellence (ACE) Re-engineering

22. 12-21-02 Research Criteria Defined –I. Summary –II. Processes –III. Deliverables –IV. Tools –V. Ease of Implementation and Sustainability in any Manufacturing Setting –VI. Miscellaneous Project Activities To Date:

23. 12-21-02 Pugh Matrix Target Sheet (New Process) Before & After Photos Standard Worksheet (New Process) Std. Work Comb. Sheet (New Process) Document Lessons Learned Create Action Item List Pitchout Checklist Complete Primary Functions, (PHF & PUF) Ideal Design Analysis ContradictionARIZ Value Stream Map Define Project Scope Area Waste Assessment -Excess Travel Distance -Multi Touch/Handoffs -Multi Touch/Handoffs -High Defect Rate -High Defect Rate -High Costs -High Costs -Excessive Inventory -Excessive Inventory -Excessive Lead Time -Excessive Lead Time Define Project CTQs (Goals & Objectives) (Goals & Objectives) Define Project Team Obtain Pledge Contract Enter Project Into Six Sigma Works Innovation Situation Questionnaire, (ISQ) MAKE THE CASE FOR ACTION Define LEARN ABOUT THE “Y” Measure LEARN ABOUT THE “X’s” Analyze PROVE THE SOLUTION Improve SUSTAIN THE SOLUTION Control Sub-Y Selection -Distance Traveled (Ft) -Floor Space (Ft2) -Floor Space (Ft2) -# of Touches -# of Touches -Mat. Handling/Ergo (#) -Mat. Handling/Ergo (#) -Quality Defects (DPMO) -Quality Defects (DPMO) -RIP/WIP/FG Inv. (ICV$) -RIP/WIP/FG Inv. (ICV$) -Cycle Time (Minutes) -Cycle Time (Minutes) -Lead Time (Minutes) -Lead Time (Minutes) Gage R&R Target Sheet (Existing Process) Standard Worksheet (Existing Process) Std. Work Comb. Sheet (Existing Process) EHS ReviewFMEA P-R Analysis P-Q Analysis Pre-work/Kick-off Checklists Complete Takt/Cycle Time Bar Chart Innovation Situation Questionnaire,( ISQ) Substance Field Analysis (Su-field Analysis) Solution Implemented & Verified All Action Items Closed Quickplace Updated With Kick-off/Pitch-out Pages List of Issues For Future AWOs Created SOPs/OMSs Updated Update/Close Project In Six Sigma Works Ideal Design Analysis Su-field Analysis Patterns of Evolution Project Activities To Date: (Lean, Six Sigma, TRIZ Macro Summary) KEY: Lean Six Sigma TRIZ

24. 12-21-02 Attention Areas: Attention Areas: Barriers To Overcome –Issue Data Storage –Meeting Agenda/Minutes –Schedule –Master Revision Control Tracker –Change Notice Process –etc. –Possible Resolution(s) Common Folders Write access to Blackboard (or equivalent)

25. 12-21-02 Summary: Time, Cost, Deliverables PROJECT OBJECTIVESBUDGETACTUALDIFFERENCEACTIONS Time (hrs) 137.5 hrs132 hrs+ 5.5 hrsnone req'd Completion Date 12/18/0212/16/02+ 2 daysnone req'd Cost $100$0+ $100none req'd Performance none req'd All Deliverables Complete per Schedule

26. 12-21-02 Next Steps: Develop Continuous Improvement Methodology –by 2/19/03 Complete Case Study Phase –by 2/19/03 Begin Business Start Up –by 2/03 Schedule Progress Report #2 –2/03

27. 12-21-02 Questions: