BWise Lean Assessment

Are safety walks performed?

Does the Supervisor and/or Team Leads participate in the safety walk on a routine basis?

Preventative measures are taken on a routine basis

Management is engaged in improving the overall safety of the facility

Employees recognize "Risks" and report unsafe conditions

There is a defined Ergonomic improvement process

Safety Indicators/Flags are included in Standardized Work Instructions

All tools have a location and are labeled

Tool locations are determined by frequency of use

Area is free of debris and oils

Daily 5S activities completed with checklist and leadership audits

Inside of cabinets / toolboxes have dedicated tool locations and labeling

Cross-functional audits routinely performed

Floors are clearly marked

Color coding is being maintained

Inventory min and max are clearly defined and adheard to

Production boards in place with SQDCP (Safety, Quality, Delivery, Cost, and People) that apply

Action items with owner and due dates are posted and reviewed daily

Andon signaling is present and monitored by supervisors and team lead

Ahead or behind schedule is clearly displayed next to production lines

Training and cross-training matrix displayed and utilized

Leaders review Key Performance Indicators (KPS's) on a routine basis

Continuous Improvement activities are track and monitored for effectiveness

Standardized Work Instructions (SWI) are posted in the area

TAKT Time is properly calculated and time of each step is part of documentation

SWI's align with Quality and Safety

Employees have been trained on SWI and are following the process

More than 1 employee trained on every job

Leadership perform SWI audits and review with the employees

Process for improving SWI exist and is followed

Work load distribution (Yamizumi charts) are posted and used for line balancing

Optimal line rate setup and correlating standard work (Playbook) is up to date and used by the supervisors

Key product quality features called out in standard work

FTQ tracked throughout the day and timely feedback system is in place

Defects are quarantined and dispositioned within one week

Employees understand key quality features pictured in standard work

Scrap used for long-term action for resolve

FTQ used for long-term action for resolve

Are key quality featured been error-proofed

Quality policy and objectives are posted and understood by all associates

Is there a Automated system that stops the process when an error is detected (Jidoka)

All aspects of the process has been considered for flow of material

Value stream maps are completed and displayed

All access points are unobstructed

Workstations are adjustable for employee height

Employees are active in defining the standard work

Employee suggestions are used

All employees are part of problem solving

Employees are engaged in Continuous Improvement events

Schedule is level loaded

Point of Use material presentation is optimized

Is there a set mix for scheduling (hiejunka)

Is there a pull system in place with re-order points

Are lead times for both make and buy materials documented

Is there a safety stock set up for each part based upon historic usage, forecast, and leadtime.

Are there clearly marked locations for materials that correspond with the ERP system

Changeover times are tracked visually and preplanned

Set up processes are documented

Set up processes are commonized

Are there visual controls for set up tools

Operational Availability is tracked

Operator performed a daily maintenance process

Scheduled Preventative Maintenance is performed on time

Is there a Predictive Maintenance system in place

All maintenance activities are tracked

KPI's in place to measure OEE in addition to MTTR or MTBF for improvements

Leadership for the area is using documented standard work

Leader standard work includes daily and weekly taskes

Leader standard work includes recognition of opportunities

Support staff for the line is using documented standard work

Evidence of cascading audits is noted and easily linked to follow-up actions

Leader standard work includes coaching and knowledge sharing

Leadership and commitment with respect to the quality management system