Fundamentals of Daily Shop Floor Management A Guide for Manufacturing Optimization and Excellence

Survival and thriving in today’s business environment require companies to continuously strive for operational excellence at all levels of the organization. Simply working to maintain existing operations is not an adequate or sustainable business strategy, especially when competing in a global market. To remain relevant, companies must adopt a process control and continuous improvement mentality as an integral part of their daily work activities. These two operational disciplines form the foundation and stepping stones for manufacturing excellence. Processes must be stable, capable, and controlled as a prerequisite for sustainable improvement. Sustainable improvements must be strategic, continuous, and focused on process optimization. Modern-day manufacturing is rapidly changing in the face of technological, geopolitical, social, and environmental developments. These challenges are altering the way we think and act to transform raw materials into finished goods. Meeting these challenges requires particular attention to how we develop and engage people and apply technology for long-term sustainability and competitive advantage. This book takes you on a journey to explore the fundamental elements, management practices, improvement methods, and future direction of shop floor management. Part 1 of this five-part book considers workplace culture, organizational structure, operational discipline, and employee accountability as the foundation for a robust manufacturing system. Part 2 studies the impact of process standardization, data analytics, information sharing, communication, and people on daily shop floor management. Once the management system has been adequately described, Part 3 concentrates on its effective execution, monitoring, and control with a deep look into the people, methods, machines, materials, and environment that make it possible. Like every good manufacturing text, efficiency and productivity are key topics. That’s why Part 4 explores various methods, tools, and techniques associated with product and process development, productivity improvement, agile methods, shop floor optimization, and manufacturing excellence. The final section, Part 5, shifts focus to emerging technologies, engaging the reader to contemplate technology’s impact on the digital transformation of the manufacturing industry.

Fundamentals of Daily Shop Floor Management: A Guide for Manufacturing Optimization and Excellence Table of Contents: Preface Figure P.1: Steps to Operational Excellence Figure P.2: Daily Shop Floor Management Roadmap Reference Acknowledgment About the Author Introduction Overview Book Contents Part 1 - Shop Floor Foundation Part 2 - Shop Floor Fundamentals Part 3 - Shop Floor Management Part 4 - Shop Floor Improvement Part 5 - Shop Floor - Next Generation The Journey to Manufacturing Excellence Daily Shop Floor Management Essential Practices of Shop Floor Management Figure I.1: Principles and Practices of Daily Shop Floor Management Summary Side Bar: 8 Steps for Improving Shop Floor Performance Key Points A Note about Supply Chain Management (SCM) Manufacturing Supply Chain Management Administration Production Distribution Figure I.2: Key Supply Chain Functions Figure I.3: Supply Chain Management (SCM) Activities Figure I.4: Production Activities Sources Part 1 - Shop Floor Foundation Overview Figure 1.0.1: The Fundamental Elements of DSFM 1.1 Organizational Culture) Introduction Lean Mindset and Culture Key Points – Culture Organizational Commitment Key Points - Commitment Organizational Alignment Key Points Side Bar: A Multicultural World Side Bar: Influencing Commitment Source 1.2 Organizational Structure Overview Figure 1.0.1A: Fundamental Elements of Daily Shop Floor Management Figure 1.2.1: Elements of Organizational Structure Organizational Framework Business Strategy Guiding Principles Routine Practices Shop Floor Management Planning Manufacturing Operations Manual (MOM) Side Bar: A Manufacturing Management System Guidelines, Procedures & Standards Shop Floor System Execution Standard Work Routines Figure 1.2.2 Operating Instructions Shop Floor System Monitoring Figure 1.2.3: System Monitoring Practices Key Process Indicators (KPI) Visual Controls Gemba Walks Performance Reviews Layered Process Audits Process Control Deviation Management Action Item List Structured Problem Solving Total Productive Maintenance Productivity Improvement Key Points Side Bar: Shop Floor Expectations 1.3 Operational Discipline Overview Figure 1.0.1B: Fundamental Elements of Daily Shop Floor Management Sustainable Discipline Improving Operational Discipline How to Maintain Operational Discipline Side Bar: Discipline Matters Key Points Sources 1.4 Employee Accountability Overview Figure 1.0.1C: Fundamental Elements of Daily Shop Floor Management Corporate Accountability Employee Accountability Side Bar: Ways to Enhance Employee Accountability Peer Accountability Shop Floor Accountability Setting Employee Expectations Employee Feedback Employee Empowerment Rewards and Consequences Treat People with Respect Communication Strategy Alignment Case Study: Are you a Management Tool or Empowered? Accountability vs. Micro-management Attitude, Behavior and Accountability Commitment and Accountability Key Points: Side Bar: Personal Accountability Part 2 - Shop Floor Fundamentals Overview Figure 2.0.1 Fundamentals of Shop Floor Management 2.1 Standardization Introduction Figure 2.1.1: Shop Floor Control and Improvement Workplace Cleanliness and Organization (5S) Procedures and Standard Work Instructions (SWI) Figure 2.1.2: Standard Work Instruction (SWI) Standard Operation Sheet (SOS) Figure 2.1.3: Standard Operation Sheet (SOS) Work Place Design Key Points 2.2 Shop Floor Data and Information Measurement Data Figure 2.2.1 Typical Manufacturing Metrics Key Process Indicators Figure 2.2.2: Input, Process, and Output indicators Figure 2.2.3: Types of Metrics Sidebar: Setting Performance Expectations Data Gathering Figure 2.2.4: Data Collection Plan Data Analysis Data Reporting Key Points 2.3 Data Visualization Overview Visual Controls for Process Management Figure 2.3.1: Visual Communication Elements Common Visual Control Displays Information or Communication Boards Figure 2.3.2: Information or Communication Board Example Figure 2.3.3: A Production Line Board Hourly Output Template Manpower Planning Boards Employee Cross-Training / Qualification Matrix Figure 2.3.4: Employee Qualification Matrix Andon Boards & Lights Tip: Chart Preparation Key Points 2.4 Shop Floor Communication Overview Figure 2.4.1: Five Shop Floor Communication Methods Machine to Machine (M2M) Communication Machine to Business (M2B) or Machine to Enterprise (M2E) Communication Shop Floor Communication Daily Meetings Figure 2.4.2: Daily Meeting Hierarchy Weekly Meetings Monthly Meetings Project Performance Reviews Gemba Walks Case Study: Gemba Walks in Action Mobile Devices Key Points 2.5 Shop Floor People People Overview Employee Empowerment Respect, Honesty, Trust Training & Development Side Bar: Developing People through Workshops Mentoring & Coaching Recognition & Reward Stakeholder Management Side Bar: Employee Satisfaction Key Points 2.6 Facilities Management Shop Floor Environment Technical Cleanliness Ergonomics ESD Utilities Key Points Part 3 - Shop Floor Management Overview Figure 3.0A: Fundamental Elements of Daily Shop Floor Management 3.1 Manufacturing System Execution Overview Figure 3.0B: Fundamental Elements of Daily Shop Floor Management Standard Work Routines Figure 3.1.1: Roles, Responsibilities, and Standard Work Routines Hierarchy Figure 3.1.2: Snapshot of Standard Work Routines. Preparing Standard Work Routines Key Points 3.2 Manufacturing System Monitoring Overview Figure 3.0C: Fundamental Elements of Daily Shop Floor Management Process Monitoring / Verification Figure 3.2.1: Shop Floor Monitoring Practices Go, See, Observe Gemba Walks Side Bar: The 10 Minute Gemba Walk Scrap Walks / Reviews Layered Process Audits Side Bar: Standard Process Audit Questions Performance Reviews Key Points 3.3 Manufacturing System Control Overview Figure 3.0D: Fundamental Elements of Daily Shop Floor Management Manufacturing System Control Figure 3.3.1: Manufacturing Practices and System Elements Process Control Figure 3.3.2: A View of Shop Floor Management Manufacturing System Integrity Standard Work Routines Deviation Management Figure 3.3.3: Deviation Management Methodology Structured Problem Solving Action Items Figure 3.3.4: Example of Action Item Format Decision Making Poka Yoke Jidoka Figure 3.3.5: Jidoka Process Flow Change Management Production Change Points Bottleneck Management Additional Manufacturing System Controls Figure 3.3.6: Manufacturing System Control Methods Key Points 3.4 Manpower Overview Figure 3.4.0 Engaging with People People Availability People Flexibility Workload Balancing Manufacturing Gages and Tools Employee Motivation Training & Experience Workplace Design & Ergonomic Working Conditions (environment) Autonomous Maintenance Labor Efficiency Employee Safety Side Bar: Covid-19 in the Workplace Key Points 3.5 Materials Overview Materials Requirements Planning (MRP) Material Deployment and Replenishment Milk Run Water Spider Material Handling and Storage Traceability Inventory Management Figure 3.5.1: Categories of Manufacturing Materials Health and safety Side Bar: Material Kitting Key Points 3.6 Manufacturing Equipment, Fixtures & Tooling Overview Equipment Optimization (Effectiveness, Reliability and Durability) Overall Equipment Effectiveness (OEE) Efficiency Losses (Big Six Losses) Figure 3.6.1: OEE Losses and Examples OEE Calculation OEE Improvement Cycle with PDCA Equipment Improvement Metrics - MTTR / MTBF Figure 3.6.2: Visual of Time to Repair and Time Between Failure Spare Parts Management Side Bar: Tips for Reducing Equipment Downtime - Good Operating Disciplines Equipment Reliability Equipment Calibration Measurement Systems Analysis Figure 3.6.3: Measurement System Analysis Overview Total Productive Maintenance (TPM) Autonomous Maintenance Systemic Maintenance Training & Qualification Asset Management Equipment Durability Key Points 3.7 Methods Overview PDCA 5S Method Deviation Management Side Bar: Investigating Abnormalities

Philip Gisi, PMP, SSMBB, has over 30 years of experience in the automotive, commercial and aerospace industries. His areas of expertise include new product development, process technology, quality management, automotive electronics, and manufacturing. He has worked internationally in multi-cultural environments and is currently involved in manufacturing operations as a manufacturing operations manager at Vitesco Technologies. Phil has a Master of Science in Engineering, a Master’s Certificate in Project Management, Lean Management Certification from the University of Michigan, Project Management Professional certification and a Six Sigma Master Black Belt (SSMBB). Phil is the author of the book “Sustaining a Culture of Process Control and Continuous Improvement: The Roadmap for Efficiency and Operational Excellence” and continues to share his experiences in Project Management, Lean Concepts, and Six Sigma Process Improvement as a DePaul University instructor for over 20 years.