RPA RATING SHEET

  • Team members use the RPA rating sheet to assess a plant in 11 categories on a scale from "poor" (1) to " excellent" (9) to "best in class" (11). The total score for all categories will fall between 11 (poor in all categories) and 121 (the best in the world in all categories), with an average score of 55. For more information on evaluative factors go to www.bus.umich.edu/rpa

  • Customer Satisfaction

  • Safety, Environment, Cleanliness, and Order

  • Visual Management System

  • Scheduling System

  • Use of Space, Movement of Materials, and Product Line Flow

  • Levels of Inventory and Work in Process

  • Teamwork and Motivation

  • Condition and Maintenance of Equipment and Tools

  • Management of Complexity and Variability

  • Supply Chain Integration

  • Commitment to Quality

  • Total Rating

RPA QUESTIONNAIRE

  • The total number of yes answers on this questionnaire is an indicator of a plant's leanness: the more yes answers, the leaner the plant. Each question should be answered yes only if the plant obviously adheres to the principle implied by the question. In case of doubt, answer no.

  • Are visitors welcomed and given information about plant layout, workforce, customers, and products?

  • Are ratings for customer satisfaction and product quality displayed?

  • Is the facility safe, clean, orderly, and well lit? Is the air quality good and are noise levels low?

  • Does visual labeling system identify and locate inventory, tools, processes and flow?

  • Does everything have its own place, and is everything stored in its place?

  • Are up-to-date operational goals and performance measures for those goals prominently posted?

  • Are production materials brought to and stored at line side rather than in separate inventory storage areas?

  • Are work instructions and product quality specifications visible at all work areas?

  • Are updated charts on productivity, quality, safety, and problem solving visible for all teams?

  • Can the current state of operation be viewed from a central control room, status board, or computer display?

  • Are production lines scheduled off a single pacing process with appropriate inventory levels at each stage?

  • Is material moved only once and as short a distance as possible? Is material move efficiently in appropriate containers?

  • Is the plant laid out in continuous product line flows rather than in "shops"?

  • Are work teams trained, empowered and involved in problem solving and ongoing improvements?

  • Do employees appear committed to continuous improvement?

  • Is a timetable posted for equipment preventative maintenance and ongoing improvement of tools and processes?

  • Is there an effective project-management process, with cost and timing goals, for new product start ups?

  • Is a supplier certification process- with measures for quality, delivery, and cost performance displayed?

  • Have key product characteristics been identified, and fail safe methods used to forestall propagation of defects?

  • Would you buy the products this operation produces?

  • Any additional comments?

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