1. Flextronics Infrastructure Montreal Lean Maturity – Plan going forward 2008

2. Assumptions
These 5 areas will be the focus of our Lean deployment plan. The Lean maturity tracker will be updated according to these production cells :
PCBA
OME 5.0
OM5K
Field Repair (LH/DX)
Shipping/Receiving/Stockroom
All new customers/products introduction will incorporate the best practices from Day 1
How to read :
Current score
Target
  1 2 3 4 5

3. Lean Maturity Tracker - Guidelines
I) Lean Leadership
 
Competency Building (ECD : Q2 2008) 1 2 3 4 5
Provide Lean training to at least 70 % of employees
Material to be used : lean awareness & simulation (simulation to be developed internally)
 
2) Plant Leadership (ECD : Q4 2008) 1 2 3 4 5
Develop Site Lean Vision (ECD : Dec 2007); communicate through GIS and line managers
Provide Lean training to at least 60 % of GM & Senior Manager; training plan (Japan tour ?)
See possibility to contract training, specific for managers (Mckenzie, Createch, …)
For each senior manager, identify the 3 kaizen for 2008 in which he will participate
 
3) Line leaders (ECD : Q2 2008) 1 2 3 4 5
For the line leaders of the target cells
Provide lean training according to kaizen plan
Identify at least 1 kaizen per year for the Line Leaders to participate
List the best practices shared between value stream

4. Lean Maturity Tracker - Guidelines
I) Lean Leadership (cont’d)
 
4) Driving Change & Boundary less (ECD : Q2 2008) 1 2 3 4 5
Update Production Playbook to incorporate Lean practices as they are developed
Identify at least 1 process to be improved for 50% of function. Proposed :
Planning & purchasing : ECO process
Customer service : Order sequencing
Finance : Process for non-moving material
Eng : NPI process
II) Lean Fundamentals
 
5) Value Stream(Q Q1 2008) 1 2 3 4 5
Update Value Stream for :
OME 5.0, OM5K, FR, Alcatel, Aethera, Blade, Verint, SMT, Receiving, Shipping
This should make more than the 50% required for Level 4
 
6) 5S (ECD : Q2 2008) 1 2 3 4 5
Implement complete 5S to score > 41% for :
SMT, OME 5.0, OM5K, FR and stockroom/receiving
Pilot on OM5K

5. Lean Maturity Tracker - Guidelines
II) Lean Fundamentals (cont’d)
 
7) Supermarket (ECD : Q2 2008) 1 2 3 4 5
Target to score 3 out of 5 on all items
For target cells : 2-bins pull system, PFEP, standard work for water spider, visual management
NVA reduction : kaizen planned for receiving and shipping (Q1 2008)
 
8) Visual Management (ECD : Q1 2008) 1 2 3 4 5
Standardize communication boards for target cells
Standardize performance metrics to be posted
Define a standard way to register actions and to react to them
III) Heijunka
 
10) Level Load (ECD : Q4 2008) 1 2 3 4 5
Get best practice from Flex Corp. and deploy
Document the standard process to level the production in order to meet 95% of the demand
Link with “visual management system” developed in NGM and OME
Best practice applicable to all cells
 
11) Sequencing: (ECD : Q2 2008) 1 2 3 4 5
Potential kaizen with Shingijutsu on Heijunka (Q1 2008)
Establish/Document a method for sequencing jobs at : SMT, production cells and shipping

6. Lean Maturity Tracker - Guidelines
IV) End To End (ETE) Pull with Zero Defect Production
 
12) Change Over (ECD : Q1 2008) 1 2 3 4 5
Assumptions : Only on SMT lines
Level 3 : Need to see if we can achieve setup time < 20 min
For this year : reduce setup time to be < 75% of baseline (kaizen in Q1 2008) ??
13) Line Config & Productivity (ECD : ?) 1 2 3 4 5
Need to understand the expectations for this requirements ??
14) Zero Defect Lines (ECD : ?) 1 2 3 4 5
Need to understand the expectations for this requirements
No definition of the auto-quality tool and list of requirements not provided
 !
15) End To End Pull:(ECD : Q4 2008) 1 2 3 4 5
Level 3 achievable, since most requirements for SMT Lines and shipping
Need to work on the forecast vs customer orders
Need to agree on a strategy since we don’t build to stock for all the products
High level of effort required to meet this requirements

7. Lean Maturity Tracker - Guidelines
IV) End To End (ETE) Pull with Zero Defect Production (cont’d)
 
16) Takt Time (ECD : Q1 2008) 1 2 3 4 5
25% of product build to takt : SMT, OME 5.0, OM5K, FR & all new customers
Takt shown on LCD screen; calculation rules for Takt and pitch clearly defined
Need to identify pacemakers for all these cell; link between pacemaker capacity and Takt
V) Jidoka
 
17) Every Abnormality (ECD : Q2 2008) 1 2 3 4 5
For target cells establish “stop line rules”; (establish link with TS rules, limit of time, …)
Stop line issues, actions, owners and dates are visible at the Shop Floor level; link with visual management
 
18) Autonomation: (ECD : Q2 2008) 1 2 3 4 5
Kaizen on Autonomation on PCBA with Shingijutsu (Q1 2008)
Minimum requirement is evidence of work on autonomation and sharing our experience; PCBA – minimum for 2008 plan; some potential on OME 5.0
Experience will be shared on Lean Mfg best practices meeting, every Thursday