Plant Manager Checklist v3

• Document No.

• F-M Site

• Conducted on

  Date

• Prepared by

• Location
  Address

Monday

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

Fast Response Meeting

• Time of meeting

  Date

• Managers participation?

  Yes

  No

  N/A

• Focus on solution?

  Yes

  No

  N/A

• Hot topics:

Back on Track

• Time of review

  Date

• TOP 10 action status

QRQC

• Time of review

  Date

• QRQC board updated?

  Yes

  No

  N/A

• QRQC discipline - step by step?

  Yes

  No

  N/A

• QRQC closed < 1 month?

  Yes

  No

  N/A

• Managers participation?

  Yes

  No

  N/A

• Minimum 1 representative per department?

  Yes

  No

  N/A

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

5S

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Cleanliness/ organization OK?

  Yes

  No

  N/A

• Is there a standard?

  Yes

  No

  N/A

• Is there an action plan?

  Yes

  No

  N/A

Shift Change

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of change

  Date

• Which shifts?

  A > C

  C > B

  B > D

  D > A

• No loss during shift change?

  Yes

  No

  N/A

• Operators acknowledge shift change procedure?

  Yes

  No

  N/A

Tuesday

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

Fast Response Meeting

• Time of meeting

  Date

• Managers participation?

  Yes

  No

  N/A

• Focus on solution?

  Yes

  No

  N/A

• Hot topics:

Back on Track

• Time of review

  Date

• TOP 10 action status

QRQC

• Time of review

  Date

• QRQC board updated?

  Yes

  No

  N/A

• QRQC discipline - step by step?

  Yes

  No

  N/A

• QRQC closed < 1 month?

  Yes

  No

  N/A

• Managers participation?

  Yes

  No

  N/A

• Minimum 1 representative per department?

  Yes

  No

  N/A

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

5S

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Cleanliness/ organization OK?

  Yes

  No

  N/A

• Is there a standard?

  Yes

  No

  N/A

• Is there an action plan?

  Yes

  No

  N/A

Shift Change

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of change

  Date

• Which shifts?

  A > C

  C > B

  B > D

  D > A

• No loss during shift change?

  Yes

  No

  N/A

• Operators acknowledge shift change procedure?

  Yes

  No

  N/A

Wednesday

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

Fast Response Meeting

• Time of meeting

  Date

• Managers participation?

  Yes

  No

  N/A

• Focus on solution?

  Yes

  No

  N/A

• Hot topics:

Back on Track

• Time of review

  Date

• TOP 10 action status

QRQC

• Time of review

  Date

• QRQC board updated?

  Yes

  No

  N/A

• QRQC discipline - step by step?

  Yes

  No

  N/A

• QRQC closed < 1 month?

  Yes

  No

  N/A

• Managers participation?

  Yes

  No

  N/A

• Minimum 1 representative per department?

  Yes

  No

  N/A

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

5S

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Cleanliness/ organization OK?

  Yes

  No

  N/A

• Is there a standard?

  Yes

  No

  N/A

• Is there an action plan?

  Yes

  No

  N/A

Shift Change

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of change

  Date

• Which shifts?

  A > C

  C > B

  B > D

  D > A

• No loss during shift change?

  Yes

  No

  N/A

• Operators acknowledge shift change procedure?

  Yes

  No

  N/A

Thursday

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

Fast Response Meeting

• Time of meeting

  Date

• Managers participation?

  Yes

  No

  N/A

• Focus on solution?

  Yes

  No

  N/A

• Hot topics:

Back on Track

• Time of review

  Date

• TOP 10 action status

QRQC

• Time of review

  Date

• QRQC board updated?

  Yes

  No

  N/A

• QRQC discipline - step by step?

  Yes

  No

  N/A

• QRQC closed < 1 month?

  Yes

  No

  N/A

• Managers participation?

  Yes

  No

  N/A

• Minimum 1 representative per department?

  Yes

  No

  N/A

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

5S

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Cleanliness/ organization OK?

  Yes

  No

  N/A

• Is there a standard?

  Yes

  No

  N/A

• Is there an action plan?

  Yes

  No

  N/A

Shift Change

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of change

  Date

• Which shifts?

  A > C

  C > B

  B > D

  D > A

• No loss during shift change?

  Yes

  No

  N/A

• Operators acknowledge shift change procedure?

  Yes

  No

  N/A

Friday

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

Fast Response Meeting

• Time of meeting

  Date

• Managers participation?

  Yes

  No

  N/A

• Focus on solution?

  Yes

  No

  N/A

• Hot topics:

Back on Track

• Time of review

  Date

• TOP 10 action status

QRQC

• Time of review

  Date

• QRQC board updated?

  Yes

  No

  N/A

• QRQC discipline - step by step?

  Yes

  No

  N/A

• QRQC closed < 1 month?

  Yes

  No

  N/A

• Managers participation?

  Yes

  No

  N/A

• Minimum 1 representative per department?

  Yes

  No

  N/A

Production Board

• Which production area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Is bottleneck identified?

  Yes

  No

  N/A

• Is there a buffer before the bottleneck?

  Yes

  No

  N/A

• Is cycle time measured and inside target?

  Yes

  No

  N/A

• Is hourly follow-up filled in?

  Yes

  No

  N/A

• Has the coordinator signed the board?

  Yes

  No

  N/A

• Is operator working 100% of the time?

  Yes

  No

  N/A

• Is there a PPS sheet opened for the biggest loss (<1wk)?

  Yes

  No

  N/A

• Is there reaction/ escalation?

  Yes

  No

  N/A

5S

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of audit

  Date

• Cleanliness/ organization OK?

  Yes

  No

  N/A

• Is there a standard?

  Yes

  No

  N/A

• Is there an action plan?

  Yes

  No

  N/A

Shift Change

• Which area?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• Time of change

  Date

• Which shifts?

  A > C

  C > B

  B > D

  D > A

• No loss during shift change?

  Yes

  No

  N/A

• Operators acknowledge shift change procedure?

  Yes

  No

  N/A

MPS

• When?

  Date

• Was it prepared in advance?

  Yes

  No

  N/A

• Did we meet previous MPS?

  Yes

  No

  N/A

• Do we meet customer demands?

  Yes

  No

  N/A

• Is workforce well dimensioned/ distributed?

  Yes

  No

  N/A

Back on Track

• When?

  Date

• TOP 10 - Manufacturing

• TOP 10 - Purchasing

• TOP 10 - Human Resources

• TOP 10 - Finance

Changeover

• Where?

  Select Foundry - ECA Foundry - Tucson Foundry - MLDB GL#1 GL#2 GL#3 DL#1 Skirt Coating Hard Anodising Auto Final Inspection Manual Final Inspection Cams External Offices

  • Foundry - ECA
  • Foundry - Tucson
  • Foundry - MLDB
  • GL#1
  • GL#2
  • GL#3
  • DL#1
  • Skirt Coating
  • Hard Anodising
  • Auto Final Inspection
  • Manual Final Inspection
  • Cams
  • External
  • Offices

• When?

  Date

• Which P/Ns?

• Is there a changeover plan?

  Yes

  No

  N/A

• Was there external preparation?

  Yes

  No

  N/A

• Did the changeover time match the plan?

  Yes

  No

  N/A

Weekly Flash

• When?

  Date

• Managers participation?

  Yes

  No

  N/A

• Focus on "back on track"?

  Yes

  No

  N/A

• Hot topics: