energy efficiency and reliability First year project rev AH BEE GOH 19 MARCH April 2011

energy efficiency and reliability Presentation titleDD.MM.YYYY2 TITLE The dependency and necessity on twin forces; ROFO model and KNOWLEDGE COMPETENCY to close the gap -execute Lean Sigma strategy

energy efficiency and reliability Presentation titleDD.MM.YYYY3 FIG GAP GAP CLOSED F1-LACK OF KNOWLEDGE F2-NO OWNERSHIP OF TOTAL PROCESS F1 AND F2 FULFILLED

energy efficiency and reliability Presentation titleDD.MM.YYYY4 APPLICATION OF F1 AND F2 FORCES TO EXECUTE LEAN SIGMA FIG Lean sigma F1- KNOWLEDGE COMPENTENCY F2-ROFO MODEL

energy efficiency and reliability Presentation titleDD.MM.YYYY5 Nonaka model Action learning Training procedure Sitting with Nellie Managers Professionals Supervisors and technicians Production workers Level 6 Level 5 Level 4 Level 3 Level 2 Level 1 R O F O Bloom taxanomy & COP Bloom taxanomy & COP F1 F2 Lean sigma control measure analysis define improve ment 7 waste removal 5S Value stream mapping Visual control Kanban pull 0ne piece flow SPC Hypothesi s/ ANOVA Takt time Knowledge competency Learning systems

energy efficiency and reliability Presentation titleDD.MM.YYYY6 SURVEY QUESTIONS AND INTERVIEW 1.SURVEY QUESTIONS.docSURVEY QUESTIONS.doc 2.Interview on Willingness and ability.pptInterview on Willingness and ability.ppt

energy efficiency and reliability Presentation titleDD.MM.YYYY7 Nonaka model Action learning Training procedure Sitting with Nellie Managers Professionals Production workers technicians Level 6 Level 5 Level 4 Level 3 Level 2 Level 1 Knowledge competency F1 Fig.7.2b Learning systems Knowledge workers Knowledge competency

energy efficiency and reliability Presentation titleDD.MM.YYYY8 RESPONSIBILTY ON- TIME CORRECTIVE ACTION FOCUS OWNERSHIP Ownership of total process F2 RR R F O R O

energy efficiency and reliability Presentation titleDD.MM.YYYY9 Lean sigma control measure analysis define improve ment 7 waste removal 5S Value stream mapping Visual control Kanban pull 0ne piece flow SPC Hypothesi s/ ANOVA Takt time

energy efficiency and reliability Presentation titleDD.MM.YYYY10 DEFINITION OF ROFO  ROFO- is a model to develop self – internalisation and motivation to own total process with the objective to execute tasks/ strategies successfully and on-time.  It stands for;  R- responsibility.  O- ownership.  F- focus.  O- on-time corrective action.  In the ROFO model, there is a fine difference between responsibility and ownership.

energy efficiency and reliability Presentation titleDD.MM.YYYY11 DEFINITION OF KNOWLEDGE COMPETENCY  The ability of the knowledge worker to apply using a combination of skills / experience, knowhow to execute a task successfully. experience knowhow skills analytical On – the job Problem- solving managerial ability

energy efficiency and reliability Presentation titleDD.MM.YYYY12 DEFINITION OF LEAN  It is a systematic approach to identifying and eliminating waste through continuous improvement, flowing the product at the pull of the customer in pursuit of perfection. From; National Institute of Standards and technology Manufacturing Extension Partnership’s Lean Network ( Practioner’s guide to Statistics and Lean Six Sigma for process improvements).

energy efficiency and reliability Presentation titleDD.MM.YYYY13 DEFINITION OF 7 WASTES 1.Over- production- producing items earlier or in bigger quantities than needed by customers. The more you produce the more you will generate wastes such as more manpower is needed and more transportation and storage areas etc. 2. Waiting- Any waiting is considered a waste such as waiting for materials or watching to serve automated machine. 3. Transportation- moving work in process (WIP) from one location to another. 4. Over processing and incorrect processing- Taking unneeded steps to processthe parts- Inefficient processing due to poor tools or jigs.

energy efficiency and reliability Presentation titleDD.MM.YYYY14 DEFINITION OF 7 WASTES 5. Excess inventory- Excess raw materials, WIP and finished goods which give rise to obsolescence. 6. Unnecessary motion- Employees have to move in an unnecessary manner which will not add any value. 7. Defects and quality problems.- Producing defective parts which have to be scrapped or reworked.

energy efficiency and reliability Presentation titleDD.MM.YYYY15 ELIMINATION OF 7 WASTES 7 Wastes In Manufacturing Rejects and Defects Seven Wastes OverProcessing InefficientTransportation Unnecessarymotion Excessinventory WaitingTimes OverProduction

energy efficiency and reliability Presentation titleDD.MM.YYYY16 DEFINITION OF SIX- SIGMA IN STATISTICAL MEANING With 4.5 sigma at the mean it achieves 3.4 defects per million with 25% design margin

energy efficiency and reliability Presentation titleDD.MM.YYYY17 DEFINITION OF SIX- SIGMA IN STATISTICAL MEANING With 6 sigma at the mean it achieves 2 defects per billion with 50% design margin

energy efficiency and reliability Presentation titleDD.MM.YYYY18 DEFINITION OF DMAIC  DMAIC stands for ;  Define the problem- understand the requirements of customer and what goals we want to achieve.  Measure the the existing process and collect relevant data.  Analyse the current performance to isolate the problem. Through analysis ( statistical and qualitatively), formulate and test hypothesis about the root cause.  Improve the problem by selecting the solution based on the ‘ analysis “ stage.  Control the improved process to ensure the targets are met

energy efficiency and reliability Presentation titleDD.MM.YYYY19 Problem exists In lean cells? Sustainable ? Process capable ? Measure sys effective ? yes No- close the project no yes DefineControl ImproveAnalyse Measure Remove variation completely yes Close the project no Close the project no Process capable ? yes no yes

energy efficiency and reliability Presentation titleDD.MM.YYYY20 Thank you very much for your attention. Any questions?