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Plant Gap Assessment

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jdavidgreen007

This document provides a gap assessment of a manufacturing plant's implementation of Toyota Production System practices across 15 areas including standardized work, visual management, quality verification, continuous improvement, and lean tools and principles. It consists of multiple sections that assess the plant's current and past performance on key statements for each TPS area on a scale of 0 to 4. The assessment is intended to identify opportunities for progress and improvement.

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TPS Plant Gap Assessment Plant Date Current Past Sec # Modules Score Score A1 Standardized Work 0.0 A2 Workplace Organization 0.0 A3 Audio & Visual Management 0.0 Gap Assessment A4 Operation Certification & Support 0.0 A5 Internal Pull & Material Conveyance 0.0 Plant % Score A6 External Pull & Transportation System 0.0 A7 Central Material Storage 0.0 0.0 A8 Lean Containers & Packaging 0.0 A9 Andon System 0.0 A10 In-Process Quality Verification 0.0 A11 Continuous Improvement Process (Kaizen) 0.0 PM Estimated A12 Problem Solving 0.0 A13 Total Productive Maintenance (TPM) 0.0 Plant % Score A14 Error Proofing / Poke-Yoke 0.0 A15 Quick Changeover (SMED) 0.0 Total 0.0 Goal Actual Days on Hand TPS Assessor: Plant Assessor: Inventory Turns Plant Manager: Hours/Vehicle Division VP: Accuracy of Assessment: Requires randomized data collection at time of Gap Assessment Quantifiable Results: Used to identify progress and opportunity. Do not try to compare plant % scores
Assessment nt % Score Estimated nt % Score % scores
A1 - Standardized Work For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Work standards are developed by the people performing the tasks Score Justification 2 Standardized Work is followed and understood by all operators (each shift). Score Justification 3 Distance operators travel to install and get parts is within proper pitch (8' - 10' pitch for linear & distance governed by cycle time for continuous line) Score Justification 4 Material presentation allows ease of access, minimizes space and reduces waste of motion Score Justification 5 Operator trips to the work bench and material are minimized to two (2) or less per cycle. Score Justification 6 Operator decisions are minimized to minimize delays or mistakes Score Justification 7 Handling of non-productive material by operators is minimized Score Justification 8 Operator movements are not restricted, obstructed or in conflict with other operators Score Justification 9 Machines, tools and equipment are located to minimize space utilization and waste of motion. Score Justification 10 Written Standardized Work Instructions are displayed at each operation contains correct information. Score Justification 11 Machines are equipped with part ejectors or transfer devices to minimize waste of motion. Score Justification 12 Operator and machines cycle independently. Score Justification 13 Visual line balance process (i.e. display wall approach) is used to distribute work elements between operators Score Justification 14 Standardized Work content and development process is periodically assessed to evaluate effectiveness. Score Justification 15 Indirect Labor work functions use Standardized Work. Score Justification Total 0
A2 - Workplace Organization For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) 1 Plant Workplace Organization (Five ?S?) guidelines have been developed Score Justification 2 Assessment and review processes is systematized to evaluate compliance to Five 'S' guidelines Score Justification 3 Is there a system in place to actively maintain, correct & improve workplace organization Score Justification 4 Effective TPM housekeeping process is in place on all shifts Score Justification 5 Safety and emergency equipment are located and organized to assure easy access and use Score Justification 6 Five ¡°S¡± Workplace Organization training is provided and improvement activities are in place Score Justification 7 Is PFEP & PFES utilized to organize Line-Side material storage Score Justification 8 Is the PFEP used to organize Bulk storage Score Justification 9 Manufacturing areas have a clear line of site Score Justification Total
dicate the rationale for your nd in some areas (25%); here, no exceptions (100%) Score 0
A3 - Audio & Visual Management For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Flow rack for small material containers are clearly marked with labels to identify the specific spot where parts are to be located. Score Justification 2 Central Material Storage locations for bulk material are clearly marked with signs to identify the specific spot where parts are to be located. Score Justification 3 All non-conforming material is visually identified. Score Justification 4 Miscellaneous material is visually identified. Score Justification 5 Storage areas, traffic aisles and pedestrian walkways are visually identified. Score Justification 6 Material container safe stacking height have visual indicators and/or instructions displayed. Score Justification 7 Work-In-Process buffer and bank locations and size limitations are visually identified. Score Justification 8 Truck delivery dock receiving times and status are visually displayed. Score Justification 9 All machines are identified and locations visually identified. Score Justification 10 Safety related visual aids provide alerts of potential hazards. Score Justification 11 Total Preventive Maintenance schedules and status are visually displayed on equipment Score Justification 12 Operation Certification display boards contain all necessary information. Score Justification 13 Problem Solving display boards communicate status of continuous improvement activity. Score Justification 14 Visual control standards/policies are established, communicated, understood. Score Justification 15 Quality issues be easily identified Score Justification 16 Material issues be easily identified Score Justification 17 Safety issues be easily identified Score Justification 18 Production issues be easily identified Score Justification
19 Operator issues be easily identified Score Justification 20 Quality, material, safety, production & operator performances are tracked and posted Score Justification Total 0
A4 - Operation Certification & Support For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Operation Certification boards are reviewed for content with employee and are current Score Justification 2 Safety Certification Checklist is posted and maintained on the Operation Certification board. Score Justification 3 Changes are reviewed by employees prior to implementation (layout, job content, work station etc¡­) Score Justification 4 Employees are empowered to make changes Score Justification 5 Employees are actively involved in continuous improvement activities Score Justification 6 Employees' suggestions are regularly solicited and reviewed. Score Justification Total 0
A5 - Internal Pull System & Material Conveyance For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 All material is replenished using a pull signal initiated by the operator (user). Score Justification 2 Material replenishment is Just-In-Time (Pulled) based on consumption. Score Justification 3 Standardized routes are used to deliver parts and pick up empty containers /dunnage. Score Justification 4 Material presentation allows ease of access, minimizes space and reduces waste of motion Score Justification 5 Material is replenished in build sequence order Score Justification 6 Signaled material is replenished promptly Score Justification 7 Pull systems are derived through PFEP Score Justification 8 All parts are populated in the PFEP Score Justification 9 PFEP is current and updated regularly Score Justification 10 Analysis is completed to justify all WIP (work in process) in order to keep Wip to a minimum level Score Justification 11 Material is stored in no more than one central location and then moves directly to point of use Score Justification Total 0
A6 - External Pull & Transportation System For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Parts are ordered based on actual consumption. Score Justification 2 Material is received when needed at a specified time (Window Receiving) Score Justification 3 Transportation logistics optimizes pick-ups, deliveries and freight. Score Justification 4 Communication system is established to rapidly provide advance warning or feedback. Score Justification 5 All suppliers provide an ASN Score Justification 6 Vendor received parts are in sequential order Score Justification Total 0
A7 - Central Material Storage For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Centralized Material Storage areas are used to temporarily hold bulk and small containers until requested Score Justification 2 Central Material Storage areas are well organized and visually managed. Score Justification 3 Process is in place to assure that Central Material Storage areas is being properly managed and maintained. Score Justification 4 Central Material Storage area inventory levels are maintained within controlled limits. Score Justification 5 Out of control situations are corrected in a timely manner (shortages and overages) Score Justification 6 Small containers are stored to assure FIFO flow and are organized in one specific location that is visually managed. Score Justification 7 Bulk containers are stored to assure FIFO flow and are organized in one specific location that is visually managed. Score Justification 8 Empty returnable bulk containers are stored/ staged within the Central Material Storage area. Score Justification 9 Empty returnable small containers are sorted in a dedicated area. Score Justification 10 Fork lift traffic is restricted to receiving docks and ¡°put away¡± storage aisles within the Central Material Storage areas. Score Justification Total 0
A8 - Lean Containers & Packaging For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Packaging business case is completed for all inbound suppliers Score Justification 2 Vendor providing all relevant information including storage location on labels Score Justification 3 Current packaging falls within Safety & Ergonomic guidelines Score Justification Total 0
A9 - Andon For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Andon System hardware and infrastructure provides status at a glance and line stop capability at a fixed position locations. Score Justification 2 Andon display boards provide status at a glance operating system and call status. Score Justification 3 Andon workstation (stack) lights provide status at a glance to quickly locate specific operators requesting support. Score Justification 4 Andon cords and buttons are readily accessible at each operation. Score Justification 5 Out of Control Audio signals (music/tones) provide audible signals when Andon system is activated. Score Justification 6 Andon system functionality provides the ability to activate and deactivate FPS (Fixed Position Stop) and is fully active Score Justification Total 0
A10 - In-process Quality Verification For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 In-process Quality Verifications (QV) stations are in place to perform standardized inspections Score Justification 2 Visual display boards are in place at each QV station to track discrepancies. Score Justification 3 Communication and awareness process is in place to rapidly communicate quality information and receive corrective action status. Score Justification 4 Standardized Work Instructions (SWI) are written and used to perform inspections. Score Justification 5 Quality alarm thresholds are established as control limits. Score Justification 6 Shipping Quality Standards (SQS) are defined, written, communicated and enforced. Score Justification 7 Successive (layered) inspections are performed by operators. Score Justification Total 0
A11 - Continuous Improvement Process (Kaizen) For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 A structured and standardized process is established to assess work activities and make improvements on an on-going basis. Score Justification 2 Teams have been trained and fully understand Continuous Improvement and are responsible for driving the process Score Justification 3 Continuous improvement plans, goals and objectives are established and achieved. Score Justification 4 Improvement ideas are replicated. Score Justification 5 Work stations / elements / activities are reviewed for the reduction & elimination of the 7 wastes Score Justification Total 0
4-12 Problem Solving (PDCA) For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Practical Problem Solving (PPS) process is in place and employees are actively engage in on-going activities Score Justification 2 Practical Problem Solving is used first as a means of resolving issues before higher level tools are applied. Score Justification 3 On-going Practical Problem Solving training is provided to all employees. Score Justification 4 Communication process is in place to transfer information from problem solving activities. Score Justification 5 Top Leadership is actively involved in mentoring and conducting regular progress reviews. Score Justification 6 Repetitive and recurring problems are tracked and Problem Solving conducted. Score Justification 7 Problem Solving goals and objectives are set for all levels of the organization. Score Justification 8 Category 1 (Do now) action items are complete within required time period Score Justification 9 Category 2 (Do Quick) action items are complete within required time period Score Justification 10 Category 3 (Do Soon) action items are complete within required time period Score Justification Total 0
A13 - Total Productive Maintenance (TPM) For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 TPM process is well defined, written, communicated and performed properly. Score Justification 2 Tracking system is in place to monitor TPM performance based on defined metrics. Score Justification 3 Leadership understands, supports and reviews TPM activities. Score Justification 4 All employees are fully trained TPM process, practices, roles, responsibilities, safety and ergonomic requirements. Score Justification 5 Operators perform minor and routine preventive maintenance functions Score Justification 6 Operators' TPM Tasks and responsibilities are written communicated and tracked. Score Justification 7 Skilled Trades perform technical maintenance functions. Score Justification 8 Monthly, weekly and daily Skilled Trades technical TPM inspections and tasks are visually displayed. Score Justification 9 TPM technical History logs are maintained. Score Justification 10 Skilled Trades are fully trained in Predictive Technologies. Score Justification 11 Operators and Skilled Trades have the ability to easily monitor the status of equipment functions, pressures, fluids, temperatures, etc. Score Justification 12 TPM activities are continuously evaluated and improvements made. Score Justification Total 0
A-14 Error Proofing / Poka-yoke For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Workers have been trained in the basics of error-proofing and there is a team responsible for analyzing production defects and identifying error proofing opportunities Score Justification 2 Error-proofing devices and methods have been implemented or are being developed to eliminate the top production defects for each work area in the plant. Score Justification 3 Error-proofing devices and methods have been applied to both manual operations and automated process. Score Justification 4 Error-proofing devices that have been installed are monitored for effectiveness, and are maintained and kept in sound working condition. Score Justification 5 Analysis has been conducted on parts and components to identify design opportunities to eliminate waste and improve productivity. Score Justification 6 Operators can stop the line when a defective unit is found or when they can not complete their process according to the SOP Score Justification 7 Manual processes or tasks have been equipped with mechanical checks to aid human judgment wherever possible. Score Justification Total 0
A15 - Quick Changeover (SMED) For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Change overs are scheduled in advance and communicated so all workers on the team know the day?s change over schedule Score Justification 2 Quick change over teams have received training on change-over time reduction procedures and are actively improving change over methods. Score Justification 3 Set-up activities have been subject to detailed process analysis techniques such as motion and time study, videotaping to identify waste, etc. Score Justification 4 Change-over time, both internal and external, is visibly tracked at each work station where change-overs are performed. Score Justification 5 As new change-over procedures are developed, they are standardized and replicated in other areas of the plant. Score Justification 6 All of the dies, fixtures, tools, fasteners, materials, parts, raw stock, operators, etc. needed for the next production run are prepared in advance to reduce change-over times Score Justification 7 All dies, fixtures, and change-over tools are stored in a neat, orderly fashion when not inuse and are maintained in good working condition. Score Justification Total 0

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Plant Gap Assessment

  • 1. TPS Plant Gap Assessment Plant Date Current Past Sec # Modules Score Score A1 Standardized Work 0.0 A2 Workplace Organization 0.0 A3 Audio & Visual Management 0.0 Gap Assessment A4 Operation Certification & Support 0.0 A5 Internal Pull & Material Conveyance 0.0 Plant % Score A6 External Pull & Transportation System 0.0 A7 Central Material Storage 0.0 0.0 A8 Lean Containers & Packaging 0.0 A9 Andon System 0.0 A10 In-Process Quality Verification 0.0 A11 Continuous Improvement Process (Kaizen) 0.0 PM Estimated A12 Problem Solving 0.0 A13 Total Productive Maintenance (TPM) 0.0 Plant % Score A14 Error Proofing / Poke-Yoke 0.0 A15 Quick Changeover (SMED) 0.0 Total 0.0 Goal Actual Days on Hand TPS Assessor: Plant Assessor: Inventory Turns Plant Manager: Hours/Vehicle Division VP: Accuracy of Assessment: Requires randomized data collection at time of Gap Assessment Quantifiable Results: Used to identify progress and opportunity. Do not try to compare plant % scores
  • 2. Assessment nt % Score Estimated nt % Score % scores
  • 3. A1 - Standardized Work For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Work standards are developed by the people performing the tasks Score Justification 2 Standardized Work is followed and understood by all operators (each shift). Score Justification 3 Distance operators travel to install and get parts is within proper pitch (8' - 10' pitch for linear & distance governed by cycle time for continuous line) Score Justification 4 Material presentation allows ease of access, minimizes space and reduces waste of motion Score Justification 5 Operator trips to the work bench and material are minimized to two (2) or less per cycle. Score Justification 6 Operator decisions are minimized to minimize delays or mistakes Score Justification 7 Handling of non-productive material by operators is minimized Score Justification 8 Operator movements are not restricted, obstructed or in conflict with other operators Score Justification 9 Machines, tools and equipment are located to minimize space utilization and waste of motion. Score Justification 10 Written Standardized Work Instructions are displayed at each operation contains correct information. Score Justification 11 Machines are equipped with part ejectors or transfer devices to minimize waste of motion. Score Justification 12 Operator and machines cycle independently. Score Justification 13 Visual line balance process (i.e. display wall approach) is used to distribute work elements between operators Score Justification 14 Standardized Work content and development process is periodically assessed to evaluate effectiveness. Score Justification 15 Indirect Labor work functions use Standardized Work. Score Justification Total 0
  • 4. A2 - Workplace Organization For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) 1 Plant Workplace Organization (Five ?S?) guidelines have been developed Score Justification 2 Assessment and review processes is systematized to evaluate compliance to Five 'S' guidelines Score Justification 3 Is there a system in place to actively maintain, correct & improve workplace organization Score Justification 4 Effective TPM housekeeping process is in place on all shifts Score Justification 5 Safety and emergency equipment are located and organized to assure easy access and use Score Justification 6 Five ¡°S¡± Workplace Organization training is provided and improvement activities are in place Score Justification 7 Is PFEP & PFES utilized to organize Line-Side material storage Score Justification 8 Is the PFEP used to organize Bulk storage Score Justification 9 Manufacturing areas have a clear line of site Score Justification Total
  • 5. dicate the rationale for your nd in some areas (25%); here, no exceptions (100%) Score 0
  • 6. A3 - Audio & Visual Management For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Flow rack for small material containers are clearly marked with labels to identify the specific spot where parts are to be located. Score Justification 2 Central Material Storage locations for bulk material are clearly marked with signs to identify the specific spot where parts are to be located. Score Justification 3 All non-conforming material is visually identified. Score Justification 4 Miscellaneous material is visually identified. Score Justification 5 Storage areas, traffic aisles and pedestrian walkways are visually identified. Score Justification 6 Material container safe stacking height have visual indicators and/or instructions displayed. Score Justification 7 Work-In-Process buffer and bank locations and size limitations are visually identified. Score Justification 8 Truck delivery dock receiving times and status are visually displayed. Score Justification 9 All machines are identified and locations visually identified. Score Justification 10 Safety related visual aids provide alerts of potential hazards. Score Justification 11 Total Preventive Maintenance schedules and status are visually displayed on equipment Score Justification 12 Operation Certification display boards contain all necessary information. Score Justification 13 Problem Solving display boards communicate status of continuous improvement activity. Score Justification 14 Visual control standards/policies are established, communicated, understood. Score Justification 15 Quality issues be easily identified Score Justification 16 Material issues be easily identified Score Justification 17 Safety issues be easily identified Score Justification 18 Production issues be easily identified Score Justification
  • 7. 19 Operator issues be easily identified Score Justification 20 Quality, material, safety, production & operator performances are tracked and posted Score Justification Total 0
  • 8. A4 - Operation Certification & Support For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Operation Certification boards are reviewed for content with employee and are current Score Justification 2 Safety Certification Checklist is posted and maintained on the Operation Certification board. Score Justification 3 Changes are reviewed by employees prior to implementation (layout, job content, work station etc¡­) Score Justification 4 Employees are empowered to make changes Score Justification 5 Employees are actively involved in continuous improvement activities Score Justification 6 Employees' suggestions are regularly solicited and reviewed. Score Justification Total 0
  • 9. A5 - Internal Pull System & Material Conveyance For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 All material is replenished using a pull signal initiated by the operator (user). Score Justification 2 Material replenishment is Just-In-Time (Pulled) based on consumption. Score Justification 3 Standardized routes are used to deliver parts and pick up empty containers /dunnage. Score Justification 4 Material presentation allows ease of access, minimizes space and reduces waste of motion Score Justification 5 Material is replenished in build sequence order Score Justification 6 Signaled material is replenished promptly Score Justification 7 Pull systems are derived through PFEP Score Justification 8 All parts are populated in the PFEP Score Justification 9 PFEP is current and updated regularly Score Justification 10 Analysis is completed to justify all WIP (work in process) in order to keep Wip to a minimum level Score Justification 11 Material is stored in no more than one central location and then moves directly to point of use Score Justification Total 0
  • 10. A6 - External Pull & Transportation System For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Parts are ordered based on actual consumption. Score Justification 2 Material is received when needed at a specified time (Window Receiving) Score Justification 3 Transportation logistics optimizes pick-ups, deliveries and freight. Score Justification 4 Communication system is established to rapidly provide advance warning or feedback. Score Justification 5 All suppliers provide an ASN Score Justification 6 Vendor received parts are in sequential order Score Justification Total 0
  • 11. A7 - Central Material Storage For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Centralized Material Storage areas are used to temporarily hold bulk and small containers until requested Score Justification 2 Central Material Storage areas are well organized and visually managed. Score Justification 3 Process is in place to assure that Central Material Storage areas is being properly managed and maintained. Score Justification 4 Central Material Storage area inventory levels are maintained within controlled limits. Score Justification 5 Out of control situations are corrected in a timely manner (shortages and overages) Score Justification 6 Small containers are stored to assure FIFO flow and are organized in one specific location that is visually managed. Score Justification 7 Bulk containers are stored to assure FIFO flow and are organized in one specific location that is visually managed. Score Justification 8 Empty returnable bulk containers are stored/ staged within the Central Material Storage area. Score Justification 9 Empty returnable small containers are sorted in a dedicated area. Score Justification 10 Fork lift traffic is restricted to receiving docks and ¡°put away¡± storage aisles within the Central Material Storage areas. Score Justification Total 0
  • 12. A8 - Lean Containers & Packaging For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Packaging business case is completed for all inbound suppliers Score Justification 2 Vendor providing all relevant information including storage location on labels Score Justification 3 Current packaging falls within Safety & Ergonomic guidelines Score Justification Total 0
  • 13. A9 - Andon For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Andon System hardware and infrastructure provides status at a glance and line stop capability at a fixed position locations. Score Justification 2 Andon display boards provide status at a glance operating system and call status. Score Justification 3 Andon workstation (stack) lights provide status at a glance to quickly locate specific operators requesting support. Score Justification 4 Andon cords and buttons are readily accessible at each operation. Score Justification 5 Out of Control Audio signals (music/tones) provide audible signals when Andon system is activated. Score Justification 6 Andon system functionality provides the ability to activate and deactivate FPS (Fixed Position Stop) and is fully active Score Justification Total 0
  • 14. A10 - In-process Quality Verification For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 In-process Quality Verifications (QV) stations are in place to perform standardized inspections Score Justification 2 Visual display boards are in place at each QV station to track discrepancies. Score Justification 3 Communication and awareness process is in place to rapidly communicate quality information and receive corrective action status. Score Justification 4 Standardized Work Instructions (SWI) are written and used to perform inspections. Score Justification 5 Quality alarm thresholds are established as control limits. Score Justification 6 Shipping Quality Standards (SQS) are defined, written, communicated and enforced. Score Justification 7 Successive (layered) inspections are performed by operators. Score Justification Total 0
  • 15. A11 - Continuous Improvement Process (Kaizen) For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 A structured and standardized process is established to assess work activities and make improvements on an on-going basis. Score Justification 2 Teams have been trained and fully understand Continuous Improvement and are responsible for driving the process Score Justification 3 Continuous improvement plans, goals and objectives are established and achieved. Score Justification 4 Improvement ideas are replicated. Score Justification 5 Work stations / elements / activities are reviewed for the reduction & elimination of the 7 wastes Score Justification Total 0
  • 16. 4-12 Problem Solving (PDCA) For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Practical Problem Solving (PPS) process is in place and employees are actively engage in on-going activities Score Justification 2 Practical Problem Solving is used first as a means of resolving issues before higher level tools are applied. Score Justification 3 On-going Practical Problem Solving training is provided to all employees. Score Justification 4 Communication process is in place to transfer information from problem solving activities. Score Justification 5 Top Leadership is actively involved in mentoring and conducting regular progress reviews. Score Justification 6 Repetitive and recurring problems are tracked and Problem Solving conducted. Score Justification 7 Problem Solving goals and objectives are set for all levels of the organization. Score Justification 8 Category 1 (Do now) action items are complete within required time period Score Justification 9 Category 2 (Do Quick) action items are complete within required time period Score Justification 10 Category 3 (Do Soon) action items are complete within required time period Score Justification Total 0
  • 17. A13 - Total Productive Maintenance (TPM) For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 TPM process is well defined, written, communicated and performed properly. Score Justification 2 Tracking system is in place to monitor TPM performance based on defined metrics. Score Justification 3 Leadership understands, supports and reviews TPM activities. Score Justification 4 All employees are fully trained TPM process, practices, roles, responsibilities, safety and ergonomic requirements. Score Justification 5 Operators perform minor and routine preventive maintenance functions Score Justification 6 Operators' TPM Tasks and responsibilities are written communicated and tracked. Score Justification 7 Skilled Trades perform technical maintenance functions. Score Justification 8 Monthly, weekly and daily Skilled Trades technical TPM inspections and tasks are visually displayed. Score Justification 9 TPM technical History logs are maintained. Score Justification 10 Skilled Trades are fully trained in Predictive Technologies. Score Justification 11 Operators and Skilled Trades have the ability to easily monitor the status of equipment functions, pressures, fluids, temperatures, etc. Score Justification 12 TPM activities are continuously evaluated and improvements made. Score Justification Total 0
  • 18. A-14 Error Proofing / Poka-yoke For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Workers have been trained in the basics of error-proofing and there is a team responsible for analyzing production defects and identifying error proofing opportunities Score Justification 2 Error-proofing devices and methods have been implemented or are being developed to eliminate the top production defects for each work area in the plant. Score Justification 3 Error-proofing devices and methods have been applied to both manual operations and automated process. Score Justification 4 Error-proofing devices that have been installed are monitored for effectiveness, and are maintained and kept in sound working condition. Score Justification 5 Analysis has been conducted on parts and components to identify design opportunities to eliminate waste and improve productivity. Score Justification 6 Operators can stop the line when a defective unit is found or when they can not complete their process according to the SOP Score Justification 7 Manual processes or tasks have been equipped with mechanical checks to aid human judgment wherever possible. Score Justification Total 0
  • 19. A15 - Quick Changeover (SMED) For each statement, please indicate the score that best represents the observed frequency in the plant and indicate the rationale for your assessment under score justification. For scoring use the following: 0= Not found anywhere; 1=Only found in some areas (25%); 2=Commonly found but not in majority (50%); 3=Very typical, some exceptions (75%); 4=Found everywhere, no exceptions (100%) Score 1 Change overs are scheduled in advance and communicated so all workers on the team know the day?s change over schedule Score Justification 2 Quick change over teams have received training on change-over time reduction procedures and are actively improving change over methods. Score Justification 3 Set-up activities have been subject to detailed process analysis techniques such as motion and time study, videotaping to identify waste, etc. Score Justification 4 Change-over time, both internal and external, is visibly tracked at each work station where change-overs are performed. Score Justification 5 As new change-over procedures are developed, they are standardized and replicated in other areas of the plant. Score Justification 6 All of the dies, fixtures, tools, fasteners, materials, parts, raw stock, operators, etc. needed for the next production run are prepared in advance to reduce change-over times Score Justification 7 All dies, fixtures, and change-over tools are stored in a neat, orderly fashion when not inuse and are maintained in good working condition. Score Justification Total 0