Where
RoadMap for Manufacturing Excellence
An Overview and Comprehensive Introduction
The PROBLEM Facing All Line Managers: Line Managers shoulder responsibility for long term corporate goals while addressing routine demands of daily operations and maintenance. This often turns into a juggling act – where more often than not a ball gets dropped. Line Managers, responsible for a host of demands, cannot effectively handle a complicated or piece- meal approach to Manufacturing Excellence.
The RoadMap Solution provides a set of basic manufacturing PRINCIPLES and TOOLS as a fully integrated solution for this problem and is particularly useful to managers in small to mid-sized plants. The TOOLS not only help to guide the technical work of Operations, Maintenance and Engineering but also address the “Organizational Excellence” aspects of the work and the "Needs of People" in a thoughtful and effective manner.
The entire RoadMap is constructed from the perspective of MINIMUM EFFECTIVE DESIGN which keeps application simple and straightforward. This “minimalist” feature is important – facilitated by a holistic and fully integrated approach - and is useful for Plants with limited resources.
Why is the RoadMap Uniquely Suited to the Quest for Manufacturing Excellence?
The use of PRINCIPLES is not generally associated with Manufacturing Excellence but they have been proven to be instrumental in leading cultural change where rigorously supported by Plant Leaders.
The RoadMap is a truly holistic approach starting with alignment of resources around required business results and adding a special section on Implementation to aaugment the PRINCIPLES and a full range of Operations, Maintenance, Engineering, and Organizational Excellence TOOLS.
It includes a thorough discussion of Leadership, Teams, and Labor Relations to foster a more complete understanding of the critical role of PEOPLE in achieving manufacturing excellence. All Plant employees are engaged in meeting Plant objectives – not just a handful of overworked supervisors and managers.
Some of the RoadMap Tools will be familiar – but the performance expectation is raised considerably by the ddocumentation of standards for excellence and ddefined roles and responsibilities. For instance most Plants will have some form of Autonomous Maintenance/TPM/Basic Care, etc. but very few of these will be implemented to the level of the RoadMap standard for Operator Rounds.
The descriptive documentation for all key TOOLS is extensive and supported by thought provoking discussion questions. Working examples are provided for all RoadMap TOOLS.
Implementation is supported by a discussion of aapplication pace; how to increase personal accountability; and dealing with organizational entropy. All of these are important but seldom discussed in most approaches to Manufacturing Excellence.
The RoadMap is intended to be evergreen and easily amenable to adding new PRINCIPLES and TOOLS. It is presented to Plant employees as a means to "organize what we know and adapt what we learn" which builds ownership as TOOLS content is developed and applied.
What you will leave with:
- A more complete understanding of Manufacturing Excellence and how it can be attained.
- A realization of why most Manufacturing Excellence initiatives fail to deliver sustainable results.
- Full access to all RoadMap support documentation and implementation aids at significantly reduced rates.
The Detail Agenda:
- Definition and detailed discussion of Manufacturing Excellence
- Review the ‘RoadMap on a Page’ summary and its application
- Review the factors enabling manufacturing competitive advantage
- Review RoadMap Principles – including Personal and Work Principles - and their application
- Review important features of the Top Level Measures for a Manufacturing Plant – including P&L, Safety, Reliability, Environmental Compliance, Product Quality, Customer Service, Manufacturing Cost (including variable, fixed and marginal), Return on Capital Investment, Asset Preservation, and Regulatory Compliance.
- Review key elements of the five RoadMap Tools categories (Alignment, Operations, Maintenance, Engineering, and Organizational Excellence)
- Outline the recommended approach to the RoadMap application
- Review the factors which affect the pace and extent of RoadMap Implementation success
- Discuss organizational entropy and other influences on the sustainability of the RoadMap application results
- Recommended Follow-up
Bob Taylor - Roadmap Development and Applications
