1) Lean culture

1) Lean culture

  • With the help of the plant manager, answer the following questions

  • Mission and valurent are displayed into the plant

  • A lean training program is in place and being followed
    (managers and all employees)

2) Roles and responsabilities

2) Roles and responsabilities

  • With the help of the plant manager, answer the following questions

Task description

  • Task description created for the plant manager, the production manager and the team leader

Leader standard work (LSW) or Position typical schedule

  • LSW created for the plant manager, the production manager, the team leader

  • LSW of the plant manager cover all shift

  • All LSW address health and safety topics, food safety topics, productivity topics and quality topics

Skill assessment

  • Skills assessment completed for the plant manager, the production manager, the team leader

  • Skills assessment created for the team member

  • Skill assessment matrix and cross training completed

3) Communication

3) Communication

  • With the help of the plant manager, answer the following questions

Three different but interconnected meetings

  • Tiered meetings

  • Tier 1- team leader with team members

  • Tier 2 - production manager with team leader

  • Tier 3 - plant manager with production manager (s) and support staff (other directors)

These subjects are addressed into tiered meetings

  • ... recents health and safety issues

  • ...recents quality and food safety issues

  • ...problems related to the lines departure have immediate corrective actions in order to avoid repeatability of problems. (Only special causes require immediate corrective action)

These subjects are addressed into other meetings

  • ...performance review of previous week

  • ...planning review of the following week

  • ...staff assignment for lunch breaks

  • ...shift change for each line

  • ...health and safety subjects (indicators, near miss incidents, incidents, audits or other health and safety subjects)

  • ...the evolution of programs and projects (Tier 4)

  • ...quality subjects (indicators, complaints, projects)

  • ...the plant evolution to the employees (indicators, projects and new products to come....)

Audit two meetings

    Meeting
  • Name of the meeting

  • Meeting starts on time

  • Participants are on time and they stay until the end

  • Animator is in place and in control

  • Agenda is respected ( all subjects are discussed)

  • Duration is respected

  • Secretary takes notes

  • Corrective actions have a responsible and a due date

  • One discussion at a time (One subject at a time)

  • Adequate conclusion for each subject

  • Participation and listening levels are adequate

3-4-5) Plant manager

Plant manager

  • With the help of the plant manager answer the following questions

  • Name :

3) Communication

  • Communicates expectations

  • Insures follow up of his/her own homeworks or to other employees.

4) Work standardization

  • Completes 85% of his/her leader standard work and it is up to date (Verify 5 of them)

  • Takes note of important situations, homework and floor tour results (verify 5 of them)

5) Performance measurement

  • Asks questions and measures in order to identify discrepancies

  • Identifies improvement opportunities

3-4-5) Production manager

Production manager

  • With the help of the production manager answer the following questions

  • Group leader
  • Name:

3) Communication

  • Communicates expectations

  • Insures follow up of his/her own homeworks or to other employees.

4) Work standardization

  • Completes 85% of his/her leader standard work and it's up to date (Verify 5 of them)

  • Takes note of important situations, homework and floor tour results (verify 5 of them)

5) Performance measurement

  • Asks questions and measures in order to identify discrepancies

  • Identifies Improvement opportunities

3-4-5) Team leader

Team leaders

  • With the help of the team leader answer the following questions

  • Team leader
  • Name:

3) Communication

  • Communicates expectations

  • Insures follow up of his/her own homeworks or to other employees.

4) Work standardization

  • Completes 85% of his/her leader standard work and it's up to date (Verify 5 of them)

  • Takes note of important situations, homework and floor tour results (verify 5 of them)

5) Performance measurement

  • Asks questions and measures in order to identify discrepancies

  • Identifies improvement opportunities

5) Performance measurement

5) Performance measurement

  • A visual system is used to measure the performance

  • Poka

  • ZP31 report

  • VBS board

  • OEE system

  • Lights system

  • The system is alive (dynamic) the information is accurate

  • The system allows the identification of discrepancies

  • The discrepancies are addressed into a corrective action

  • Just do it

  • Problem solving method

  • Projects

6) Problem solving

6) Problem solving

  • With the help of the plant manager, answer the following questions

  • A system is in place to list the problems

  • Notifications (ZAVIS)

  • Lists in One note

  • Excel sheet

  • Communication boards (handwritten notes)

  • The estimated finish date for each problem is in the future and is accurate

  • Choose at least two problems and answer the following questions

  • Problem
  • Name:

  • A problem solving method is in place

  • 5 why's

  • 7M Ishikawa- fish bone diagram

  • Pareto

  • A3 - DMAIC

  • One problem per resolution

  • Root cause analysis well identified

  • The actions taken to solve the problem seem ensure a permanent solution

7) Projects management

7) Projects management

  • With the help of the plant manager, answer the following questions

  • Capex file is used to list the investment projects

  • One of these tools is used to list all the projects : OneNote, X-Matrix, Excel document.

  • Choose at least two projects and answer the questions

  • Project
  • Name:

  • Project charter or an equivalent exists and has been approved

  • Project charter or an equivalent describes the problem statement

  • Project charter or an equivalent describes the goals

  • Project charter or an equivalent describes the activities (milestones)

  • Accomplishment project assessment completed (final report with a resume of the problems, actions taken and gains obtained)

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