Page 322 - How To Implement Lean Manufacturing

296 Cha pte r Ni netee n

In short, process Levels 1 through 3 work to achieve a process that has met all qual-
ity standards of the customer. Levels 4 through 5 address the issues of quantity control.
Generally, the development of a process should follow a natural pattern as outlined
here and in this order. Although this is not true for all work stations or even all complex
process flows, it is a good general guideline and will serve you well in describing the
level of process maturity. The levels are labeled as Level 1 through Level 5 and are char-
acterized by the following:
1. Level 1
a. A Level 1 process has a set of documentation that allows a firm to design and
build a product, as well as a means to assess quality and delivery capabilities.
Documentation usually includes:
i. A complete up-to-date drawing of the part or assembly, including any
part or subassembly requirements. All construction goals are clearly
understood, with product and process critical characteristics defined
and agreed upon
ii. A test specification, plus all operational definitions to determine if a
product is accepted or rejected
iii. Packaging specifications
iv. A plot plan
v. A flow chart
vi. A PFMEA
vii. A Part Number Control Plan
viii. Appropriate work instructions, including all instruction for rework
ix. Demand rates or projections good enough for production scheduling
b. Nearly all of the 20 Lean techniques should be designed into the process. For
example, cells, multiskilled workers, kanban, takt time, leveling, and standard
work, to name a few, should be built into the design.
c. Since a Level 1 process is basically a preproduction condition, successful
attainment would include such items as completion of PPAP and run-at-rate
to meet customer requirements.
2. Level 2
a. A Level 2 process has all the characteristics of a Level 1 process, plus the
production process flows (has an actual process routing) in full accordance
with the Level 1 documentation. Specifically:
i. Raw materials enter the process only as noted; products leave only as
documented.
ii. No other intermediate assemblies, and so on, enter or leave the process
unless documented on the flow.
iii. All work in process flows just as in the flow chart. All good product
follows the process flow diagram. All scrap and potential reworked
product are properly segregated from the normal process flow. All
scrapped and reworked products follow the prescribed process flow
for scrap and rework.