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Definition : Workers can perform multiple tasks within one process. Workers can perform tasks in more than one process. Management monitors resources, ergonomics and job rotation. Quick response in deployment of resources to changes in product mix and customer demand. Instructions: Fill in the number of “quarters” for each circle that correspond to the level observed in the plant. Use the questions on the back of this sheet to aid in evidence gathering. Divide the number of quarters shaded by the total number of quarters to determine percent implementation.

Level

1

Measurable % Evident Workers are adequately trained to do the job they are assigned to do. Processes are aligned to facilitate material flow. Minimal changes in demand can be accommodated.

Workers are proficient in their assigned job and capable of performing other similar tasks in their area. Some cross-training and job rotation occurs. Some changes in demand can be accommodated.

Workers are proficient in a variety of tasks. Cross-training is planned and job rotation is regularly scheduled. Most changes in demand can be accommodated.

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The plant has autonomous machines (self-inspecting - shut down when an abnormality occurs, auto-loading and ejecting, do not need worker while cycling). Some processes are optimized to facilitate material flow. There is evidence of extensive cross-training & job rotation.

Almost all changes in demand can be accommodated. All processes are optimized to facilitate material flows. Standardized work sheets describe alternate staffing and job descriptions for fluctuations in demand. Workers are highly proficient at tasks even when demand fluctuates. Machine/man ratios for each task are

optimized.

Flexible Operations Assessment = Filled Quarters / Total Quarters ____/_20_ = _____ %

Key: 0: 1: 2:

0% - Not found anywhere

3: 4: 75% - Very typical, some exceptions 100% - Everywhere in plant, no exceptions 25% - Only seen in some areas 50% - Commonly found but not in the majority of cases

Flexible Operations Evidence Gathering

Questions to ask people in the plant to aid in your assessment...

? Are workers adequately (well) trained in their assigned job(s)? ? Have part travel distances been minimized?

? Is all equipment arranged in a product vs. process focus? ? Is equipment automated where applicable?

? Are processes aligned for excellent material flow? ? Can lines easily accommodate fluctuations in demand?

? Do standardized work sheets describe alternate staffing and job descriptions for each operator when numbers of operators and responsibilities change? ? Can workers easily rotate to other jobs?

? Do team members rotate jobs on a regular basis?

? Is standardized work defined for different production rates? ? Is there a well-defined plan to cross-train workers? Enablers

Disablers Evidence of Best Practices

Kaizen

Definition : Kaizen is continuous improvement. Constant, incremental, small scale progress. Kaizen is measured by standardized work. Kaizen differs from “kaikaku” or large scale innovation which is top-down, fundamental change. Instructions: Fill in the number of “quarters” for each circle that correspond to the level observed in the plant. Use the questions on the back of this sheet to aid in evidence gathering. Divide the number of quarters shaded by the total number of quarters to determine percent implementation.

Level

1

Measurable % Evident Improvements have been made mainly through capital investments or new products. There is a continuous improvement plan. Improvements are made, and sometimes sustainable.

Ideas for continuous improvements are asked from employees and there is evidence that they are implemented. The continuous improvement plan is generally followed. Some employee involvement. Improvements are made, and generally sustainable.

There is a well-defined strategy for continuous improvement with evidence of measurable results in most areas. Improvements are sustained and built upon by further kaizens. Most employees have been involved.

All employees have been trained in the basics of kaizen and have been affected by a kaizen project. Employees know the 7 wastes, identify waste in their processes and work to reduce the waste. High management attention to developing a kaizen culture.

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There is a clearly communicated strategy for continuous improvement with the necessary resources and organization planned and implemented. Projects are structured and continuous; successes are recognized and expanded throughout the plant. It is clearly evident that Kaizen

teams are a way of life.

Kaizen Assessment = Filled Quarters / Total Quarters ____/_20_ = _____ %

Key: 0: 1: 2:

0% - Not found anywhere

3: 4: 75% - Very typical, some exceptions 100% - Everywhere in plant, no exceptions 25% - Only seen in some areas 50% - Commonly found but not in the majority of cases

Kaizen Evidence Gathering

Questions to ask people in the plant to aid in your assessment...

? Are employees involved in continuous improvement throughout the plant? ? Is there a clearly communicated strategy for continuous improvement? ? Are resources available to support the improvement strategy? ? Is management support for continuous improvement evident?

? Are continuous improvement results measured and communicated?

? Are all employees trained (or scheduled to be trained) in the basics of kaizen? ? Do all employees know the 7 Kinds of Waste?

? Are all employees encouraged to ID and eliminate waste in their area? ? Are successes recognized throughout the plant?

? Is a suggestion system in place to stimulate idea generation? ? Are there any incentive programs for continuous improvement? Enablers

Disablers Evidence of Best Practices

Error proofing

Definition : Also known as mistake proofing, poka-yoke or zero-defects. The systems that support the process are mistake proofed to reduce/eliminate all possibility of error in all process steps. Operators “get it right the first time” and management provides the tools. No inspection, no rework! A defect is defined as any error in assembly, equipment, visual appearance, etc. Instructions: Fill in the number of “quarters” for each circle that correspond to the level observed in the plant. Use the questions on the back of this sheet to aid in evidence gathering. Divide the number of quarters shaded by the total number of quarters to determine percent implementation.

Level

1

Measurable % Evident Initial efforts are in place to evolve from inspection and containment to prevention. The

process is sometimes stopped when defects are detected. Management tolerance for rework is decreasing.

In general, defects are detected at the next downstream operation. There is evidence that rework and inspection are decreasing. Employees are empowered to stop the process when a defect occurs

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In general, defects are detected after they occur, but before they reach the next downstream operation. Employees are encouraged to stop the process when a defect occurs. Some error proofing devices in evidence (e.g. go/no go torque measurements). Management attention is

focused on defect prevention. Defects are often prevented within the station, where feasible, detected within the station if not feasible. There is evidence that error proofing philosophy has been applied across the plant. Error proofing devices are common. Most employees are trained in error proofing.

Management has low tolerance for rework. Where automation exists, it is self-inspecting and will shut down when defects are detected. In manual operations plant wide, error proofing devices have been developed to build in quality at each step and to prevent defects at their source to prevent recurrence. Line stops result in rapid response to defects from management. There is evidence that the design was error proofed prior to launch. Rework is minimal. First run capabilities are approaching 0 PPM as a result of management attention to error proofing.

Error proofing Assessment = Filled Quarters / Total Quarters ____/_20_ = _____ %

Key: 0: 1: 2:

0% - Not found anywhere

3: 4: 75% - Very typical, some exceptions 100% - Everywhere in plant, no exceptions 25% - Only seen in some areas 50% - Commonly found but not in the majority of cases