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Evidence of Winning Strategies
A. Employee Involvement Teams
• Visual evidence
o Pictures
o Minutes
o Skills boards
o Projects
o Cost-saving ideas
o Problem Solving worksheet
o Location for meetings
o Schedule for team meetings
• Show on-going progress
o Project dates (current and future)
o Skill boards up-to-date
o Problem solving sheets up-to-date
o Minutes of meetings
o Cost of meetings
o Cost-saving ideas
• Soft skills
o Respecting each other
o Working well together
o Reaching group consensus
o Knowing how to have a meeting
B. Total Productive Maintenance (TPM)
• History of repair
• Downtime logs
• Tool changeover history
• Repair parts lists
• Schedules for autonomous maintenance
• Checklist by operator
C. Problem Solving
• Problem Solving sheets are posted and up-to-date
• Comparisons of before and after
• Current and daily dates
• Measurement of root cause
• Evidence of permanent change
• Employee-driven teams
D. Kaizen
• Team improvements
• Project review schedule with management input
• Plan-Do-Check-Act (PDCA) chart
o project control
o sheets
o timelines
• Problem Solving activity
• Ideas history
o pictures and list of ideas
• Standardized work charts
o Non-value-added activities identified
• Proposed process change
o Tooling and equipment
• Picture and list of successes
E. Single Minute Exchange of Die (SMED)
• Team changeovers
• 5 S tools
• Standardized procedures for change including preventive maintenance
• Tool and materials address locations
• Standardized block guides
• Quick disconnect hoses
• Centering blocks and guides
• Shut-height standardized
• Quick lock down - hydraulic and manual
• Standardized stop pins
• Documented times
o Temperatures
o Press
o Fill rates
o Color coding
o Materials standards
• Dedicated press or injection press
• Planned tool location for each press
• Die change signal
• Check fixtures and locations
Next: Training programs for lean manufacturing
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