| Material |
Response |
| 1. |
Kanban replenishment processes
visible (Internal & external)? |
|
|
| 2. |
What is the overall inventory
turnover, including Finished Goods, WIP and Purchased/Raw material? |
|
|
| 3. |
What portion of the facility’s
layout minimizes material handling? |
|
| |
| Leadership
& Teaming |
Response |
| 4. |
What is the organization type? |
|
|
| 5. |
Our front line employees are
actively involved in change management, percentage of the time? |
|
|
| 6. |
To what extent do people have
job security? |
|
|
| 7. |
What is the annual personnel
turnover |
|
|
| 8. |
What percentage of personnel
(ALL Personnel) have received at least eight hours of formal
team training? |
|
|
| 9. |
What percentage of personnel
are active members of formal work teams, quality teams, or problem-solving
teams? |
|
| |
| Human
Resources & Software |
Response |
| 10. |
Front Line Supervision has
been trained in WC “supervision”, leadership techniques
percentage for your company? |
|
|
| 11. |
Culture indicative of and can
support change? |
|
|
| 12. |
Software/system support “lean”
operations |
|
|
| 13. |
Company has an aligned recognition
and rewards system? |
|
| |
| Processes |
Response |
| 14. |
How many large-scale machines
or single-process areas are in the plant through which 50% or
more of different products must pass? |
|
|
| 15. |
Company has program in-place
to reduce process steps? |
|
|
| 16. |
How easy is it to shift output
when the product mix changes? |
|
|
| 17. |
How easy is it to alter the
total production rate by +/-15%? |
|
|
| 18. |
What is management's target
operating capacity for individual departments or machines? |
|
|
| 19. |
Viable new product introduction
process in place? |
|
| |
| Maintenance |
Response |
| 20. |
Equipment is State-of-the-art? |
|
|
| 21. |
Equipment and tooling are well
maintained? |
|
|
| 22. |
Does maintenance have and follow
a defined preventive schedule? |
|
|
| 23. |
How often does unplanned maintenance
happen? |
|
|
| 24. |
What is the overall average
availability of plant equipment? Ready for use time? |
|
| |
| Layout
& Handling |
Response |
| 25. |
What portion of total space
is used for storage and material handling? |
|
|
| 26. |
What portion of the plant space
is organized by function or process type? |
|
|
| 27. |
5S Housekeeping process in
use? |
|
|
| 28. |
How would you rate overall
housekeeping and appearance of the plant? |
|
|
| 29. |
How well could a stranger walking
through your plant identify the processes and their sequence? |
|
|
| 30. |
Facility has a cellular/focused
factory layout? |
|
| |
| Suppliers |
Response |
| 31. |
What is the average number
of suppliers for each raw material or purchased item? |
|
|
| 32. |
Materials management is visible
through an effective Sales, Production, Inventory (SPI) Planning
process? |
|
|
| 33. |
What portion of raw material
& purchased parts comes from qualified suppliers with no
need for incoming inspection? |
|
|
| 34. |
What portion of raw material
and purchased items is delivered directly to the point of use
without incoming inspection or storage? |
|
|
| 35. |
What portion of raw materials
and purchased parts is delivered more than once per week? |
|
| |
| Setups |
Response |
| 36. |
What is the average overall
setup time (in minutes) for major equipment? |
|
|
| 37. |
What portion of machine operators
have had formal training in Rapid Setup techniques? |
|
|
| 38. |
To what extent are managers
and workers measured and judged on setup performance? |
|
| |
| Quality |
Response |
| 39. |
What portion of total employees
have had basic SPC training? |
|
|
| 40. |
What portion of operations
are controlled with Statistical Process Control (SPC)? |
|
|
| 41. |
Quality is high and not an
issue? |
|
|
| 42. |
What is the overall defect
rate? |
|
| |
| Scheduling |
Response |
| 43. |
What portion of work-in-process
flows directly from one operation to the next without intermediate
storage? |
|
|
| 44. |
What portion of work-in-process
is under Kanban? |
|
|
| 45. |
What is the on-time delivery
performance? |
|
| |
| 46. |
Shop lead time is monitored
and measured? |
|
|
| 47. |
Production is in-sync with
demand? |
|
|
| |
| Contact Form |
|
(* = required field )
|
Practice Areas
Overview