FUNDAMENTALS OF DAILY SHOP FLOOR MANAGEMENT : a guide for manufacturing optimization and... excellence

Survival and thriving in today’s business environment require companies to continuously strive for operational excellence at all levels of the organization. Simply working to maintain existing operations is not an adequate or sustainable business strategy, especially when competing in a global market. To remain relevant, companies must adopt a process control and continuous improvement mentality as an integral part of their daily work activities. These two operational disciplines form the foundation and stepping stones for manufacturing excellence. Processes must be stable, capable, and controlled as a prerequisite for sustainable improvement. Sustainable improvements must be strategic, continuous, and focused on process optimization. Modern-day manufacturing is rapidly changing in the face of technological, geopolitical, social, and environmental developments. These challenges are altering the way we think and act to transform raw materials into finished goods. Meeting these challenges requires particular attention to how we develop and engage people and apply technology for long-term sustainability and competitive advantage. This book takes you on a journey to explore the fundamental elements, management practices, improvement methods, and future direction of shop floor management. Part 1 of this five-part manuscript considers workplace culture, organizational structure, operational discipline, and employee accountability as the foundation for a robust manufacturing system. Part 2 studies the impact of process standardization, data analytics, information sharing, communication, and people on daily shop floor management. Once the management system has been adequately described, Part 3 concentrates on its effective execution, monitoring, and control with a deep look into the people, methods, machines, materials, and environment that make it possible. Like every good manufacturing text, efficiency and productivity are key topics. That’s why Part 4 explores various methods, tools, and techniques associated with product and process development, productivity improvement, agile methods, shop floor optimization, and manufacturing excellence. The final section, Part 5, shifts focus to emerging technologies, engaging the reader to contemplate technology’s impact on the digital transformation of the manufacturing industry. Cover Half Title Title Page Copyright Page Table of Contents Preface Acknowledgment About the Author Introduction Overview Book Contents Part 1: Shop Floor Foundation Part 2: Shop Floor Fundamentals Part 3: Shop Floor Management Part 4: Shop Floor Improvement Part 5: Next-Generation Shop Floor The Journey to Manufacturing Excellence Daily Shop Floor Management Essential Practices of Shop Floor Management Summary Key Points A Note about Supply Chain Management (SCM) Manufacturing Supply Chain Management Administration Production (e.g. Manufacturing) Distribution Source Part I: Shop Floor Foundation Overview Chapter 1.1: Organizational Culture Introduction Lean Mindset and Culture Organizational Commitment Organizational Alignment Source Chapter 1.2: Organizational Structure Overview Organizational Framework Business Strategy Guiding Principles Routine Practices Shop Floor Management Planning Manufacturing Operations Manual Guidelines, Procedures, and Standards Shop Floor System Execution Standard Work Routines Shop Floor System Monitoring Key Process Indicators Visual Controls Gemba Walks Performance Reviews Layered Process Audits Process Control Deviation Management Action Item List Structured Problem-Solving Total Productive Maintenance Productivity Improvement Key Points Chapter 1.3: Operational Discipline Overview Sustainable Discipline Improving Operational Discipline How to Maintain Operational Discipline Key Points Source Chapter 1.4: Employee Accountability Overview Corporate Accountability Employee Accountability Peer Accountability Shop Floor Accountability Setting Employee Expectations Employee Feedback Employee Empowerment Rewards and Consequences Treat People with Respect Communication Strategy Alignment Accountability vs. Micro-Management Attitude, Behavior, and Accountability Commitment and Accountability Key Points Part II: Shop Floor Fundamentals Overview Chapter 2.1: Standardization Introduction Workplace Cleanliness and Organization (5S) Standard Procedures and Work Instructions Standard Operation Sheet Workplace Design Key Points Chapter 2.2: Shop Floor Data and Information Measurement Data Key Process Indicators Data Gathering Data Analysis Data Reporting Key Points Chapter 2.3: Data Visualization Overview Visual Controls for Process Management Common Visual Control Displays Information or Communication Boards Manpower Planning Boards Employee Cross-Training or Qualification Matrix Andon Boards and Lights Display Chart Preparation Tips Key Points Chapter 2.4: Shop Floor Communication Overview Machine to Machine (M2M) Communication Machine to Business (M2B) or Machine to Enterprise (M2E) Communication Shop Floor Communication Daily Meetings Weekly Meetings Monthly Meetings Project Performance Reviews Gemba Walks Mobile Devices Key Points Chapter 2.5: Shop Floor People Overview Employee Empowerment Respect, Honesty, and Trust Training and Development Mentoring and Coaching Recognition and Reward Stakeholder Management Key Points Chapter 2.6: Facilities Management Shop Floor Environment Technical Cleanliness Ergonomics Electrostatic Discharge Utilities Key Points Source Part III: Shop Floor Management Overview Key Points Chapter 3.1: Manufacturing System Execution Overview Standard Work Routines Preparing Standard Work Routines Key Points Chapter 3.2: Manufacturing System Monitoring Overview Process Monitoring/Verification Go, See, Observe Gemba (Management) Walks Scrap Walks/Reviews Layered Process Audits Performance Reviews Key Points Chapter 3.3: Manufacturing System Control Overview Manufacturing System Control Process Control Manufacturing System Integrity Standard Work Routines Deviation Management Deviation Management Tips Structured Problem-Solving Action Items Decision-Making Poka-Yoke (Error Proofing) Jidoka Change Management Production Change Points Bottleneck Management Additional Manufacturing System Controls Key Points Chapter 3.4: Manpower Overview People Availability People Flexibility Workload Balancing Manufacturing Gauges and Tools Employee Motivation Training and Experience Workplace Design and Ergonomics Working Conditions (Environment) Autonomous Maintenance Labor Efficiency Employee Safety Key Points Source Chapter 3.5: Material Overview Material Requirements Planning Material Deployment and Replenishment Milk Run Water Spiders Material Handling and Storage Traceability Inventory Management Health and Safety Key Points Sources Chapter 3.6: Manufacturing Equipment, Fixtures, and Tooling Overview Equipment Optimization (Effectiveness, Reliability, and Durability) Overall Equipment Effectiveness Efficiency Losses OEE Calculation OEE Improvement Cycle (with Plan-Do-Check-Act [PDCA]) Equipment Improvement Metrics (MTTF and MTBF) Spare Parts Management Equipment Reliability Equipment Calibration Measurement Systems Analysis Total Productive Maintenance Autonomous Maintenance Systemic Maintenance Training and Qualification Asset Management Equipment Durability Key Points Source Chapter 3.7: Methods Overview Plan-Do-Check-Act 5S Method Deviation Management Change Management Structured Problem-Solving Just-in-Time Inventory Policy Deployment Single-Minute Exchange of Die Agile Manufacturing Summary Key Points Chapter 3.8: Manufacturing Environment Overview Building Layout/Design Ergonomics Safety Lighting Temperature Ventilation Air Quality Air Current Noise Humidity Facility Space Vibration Key Points Source Part IV: Shop Floor Improvements Overview Chapter 4.1: Product and Process Development Overview Design for Manufacturing Design for Six Sigma Design and Process FMEA Key Points Source Chapter 4.2: Productivity Improvement Overview Incremental Improvement Sustainable Improvement Improvement Methods Quality Circles Employee Idea Management Set-Up and Changeover (SMED) Six Sigma DMAIC Toyota Kata Projects Value Analysis Kaizen Events Jishuken (Self-Study) Workshops Productivity Improvement Tools and Techniques Go, See, Observe, Understand, and Confirm Workplace Design/Ergonomics Process Mapping Six Thinking Hats Workload Balancing Production Leveling Yamazumi Charts/Boards Buffer Management Best Practice Sharing Lessons Learned Key Points Sources Chapter 4.3: Agile Methods Overview Application of Agile Practices Predictive, Iterative, and Incremental Life Cycles Daily Stand-Up Meetings Retrospectives Co-Location Key Points Source Chapter 4.4: Shop Floor Optimization Overview Knowledgeable and Skilled People Cooperation and Collaboration Available and Reliable Equipment Materials Management Practices and Procedures Operator Movement Optimization Material Flow Optimization Environmental Optimization Optimization Methods, Tools, and Techniques Process Characterization Design of Experiments Response Surface Methods Process Flow Optimization Methods Value Stream Mapping/Design Constraint Management Spaghetti Diagram Lessons Learned Summary Key Points Sources Chapter 4.5: Manufacturing Excellence Overview Enterprise Alignment Organizational Structure Operational Discipline Employee Accountability Agility Mindset Employee Development Process Control Continuous Improvement Technological Advancement Customer Satisfaction Supplier Partnerships Lessons Learned Shop Floor Practices Key Points Part V: Next Generation Shop Floor Overview Industry 4.0 Expectations Digital Transformation Productivity Improvements That Make a Difference Part 1 : Technical Innovations Collaborative Robots (Cobots) Robotic Process Automation (RPA) Automated Guided Vehicles (AGVs) Micro AGVs Smart Glasses Centralized (Automated) Inspection (AOI) Fixed Process Cell Autonomous (Digital) Workforce Part 2 : Thinking Differently Big Data Equipment Robustness (Reliability and Durability) – A Case for Data Analytics Predictive Equipment Maintenance Spare Parts Management 3D Printing of Spare Parts Suitcase Tester (or Other On-Site Testing Devices) Vendor Managed Inventory Machine Learning Modular Product Architecture Mobile Devices Gamification Environmental Sustainability Key Points Sources Appendix 1 - Daily Shop Floor Management Checklist Appendix 2 - Manufacturing Operations Manual – Example Purpose Six Phases of Process Maturity Appendix 3 - Standard Work Routines Appendix 4 - Tips for Shop Floor Monitoring Appendix 5 - Single-Minute Exchange of Die (SMED) Workshop Appendix 6 - Jishuken Workshop Methodology Overview Workshop Pre-Work (2 to 4 Weeks Before) Workshop Activities (Day 1) Workshop Activities (Day 2+) Workshop Closure Activities Post-Workshop Activities Appendix 7 – Acronyms and Terms Index Survival and thriving in today’s business environment require companies to continuously strive for operational excellence at all levels of the organization. Simply working to maintain existing operations is not an adequate or sustainable business strategy, especially when competing in a global market. To remain relevant, companies must adopt a process control and continuous improvement mentality as an integral part of their daily work activities. These two operational disciplines form the foundation and stepping stones for manufacturing excellence. Processes must be stable, capable, and controlled as a prerequisite for sustainable improvement. Sustainable improvements must be strategic, continuous, and focused on process optimization. Modern-day manufacturing is rapidly changing in the face of technological, geopolitical, social, and environmental developments. These challenges are altering the way we think and act to transform raw materials into finished goods. Meeting these challenges requires particular attention to how we develop and engage people and apply technology for long-term sustainability and competitive advantage. This book takes you on a journey to explore the fundamental elements, management practices, improvement methods, and future direction of shop floor management. Part 1 of this five-part book considers workplace culture, organizational structure, operational discipline, and employee accountability as the foundation for a robust manufacturing system. Part 2 studies the impact of process standardization, data analytics, information sharing, communication, and people on daily shop floor management. Once the management system has been adequately described, Part 3 concentrates on its effective execution, monitoring, and control with a deep look into the people, methods, machines, materials, and environment that make it possible. Like every good manufacturing text, efficiency and productivity are key topics. That’s why Part 4 explores various methods, tools, and techniques associated with product and process development, productivity improvement, agile methods, shop floor optimization, and manufacturing excellence. The final section, Part 5, shifts focus to emerging technologies, engaging the reader to contemplate technology’s impact on the digital transformation of the manufacturing industry. This book takes take you on a journey to explore the fundamentals elements, management practices, improvement methods, and future direction of shop floor management. agile,methods;,daily,shop,floor,management;,data,visualization;,employee,accountability;,facilities,management;,manufacturing,environment;,manufacturing,equipment;,manufacturing,system,control;,manufacturing,system,execution;,manufacturing,system,monitoring;,material,requirements,planning;,next-generation,shop,floor;,operational,discipline;,organizational,culture;,organizational,structure;,process,development;,process,standardization;,productivity,improvement;,shop,floor,communication;,shop,floor,data agile methods,daily shop floor management,data visualization,employee accountability,facilities management,manufacturing environment,manufacturing equipment,manufacturing system control,manufacturing system execution,manufacturing system monitoring,material requirements planning,next-generation shop floor,operational discipline,organizational culture,organizational structure,process development,process standardization,productivity improvement,shop floor communication,shop floor data