Manufacturing Assessment

What’s Included:

• Value Stream Map (VSM)
• Product Quantity, Product Routing (PQPR) Matrix
• Shingo Audit

Value Stream Map (VSM)

A value stream (VSM) is the series of steps that occur to provide a product, service and/or experience the customer desires.   The map includes: the amount of potential opportunity the manufacturing operation must produce more product, the amount of variation the final product had relative to customer specifications,  the amount of customer specification consumed by measurement system error,  how well data is used to manage the production processes,  and where processes chinould be modified to reduce inefficiencies. Samples of product quality are reviewed with standard statistical protocols to understand how well the product complies with the customer specifications.  This statistical analysis includes checking for data stability and normality of the data, and then calculating capability indices.  Measurement systems evaluations are requested to understand the degree of precision and accuracy the systems used to run the processes and to measure the final product quality. 

Product Quantity, Product Routing (PQPR) Matrix

The Product Quantity / Process Routing (PQPR) matrix provides an overview of the products and the processes they are routed.  The PQPR matrix shows the number of employees that work in each of the processes and what metrics are used.  The matrix includes gross revenue, gross profit % margin, and sales in pounds.  The current OEE as well as performance, availability, and Yield data is listed for each product.   Overall equipment effectiveness (OEE) is computed:  Performance – This is a comparison of the amount that could be produced until the best of conditions contrasted with the amount produced,  availability – This is the percentage of the time a manufacturing unit is scheduled to be in production vs. the amount of time it is in production, and yield – This is the percentage of product that conforms to the product spec (at that stage of the process).

Shingo Audit

The Shingo model has four dimensions.  Cultural Enablers – The guiding principles are to Lead with Humility and respect every individual.  The supporting principles are; nurture long term relationships with supplier, customers, and employees, empower and involve everyone, develop people, and assure a safe environment.  Continuous Improvement – The guiding principles are to Focus on process, embrace scientific thinking, flow and pull value, assure quality at the source, and seek perfection.  The supporting principles are; stabilize processes, rely on data, standardize processes, insist on direct observation, focus on value stream, keep it simple and visual, identify and eliminate waste, integrate improvement with work.  Enterprise Alignment – The guiding principles are to create constancy of purpose and think systematically.  The supporting principles are; see reality, focus on long-term, align systems, and align strategy.  Results – The guiding principle is to create value for the customer.  The supporting principles are; measure what matters, align behaviors with performance, and identify cause and effect relationships.

Outcomes:

• VSM identification
• PQPR matrix. Extensive matrix that provide the data box of a value stream map
• Shingo audit score for each of (4) dimensions
• Shingo recommendations