Page 323 - How To Implement Lean Manufacturing

Assessment Tools 297

iv. All critical processes or process steps have completed and acceptable
gauge studies.
v. All process steps are statistically stable.
vi. Work instructions are in place and adequately describe the work. Work
instructions are scrupulously followed.
b. Again, with a Level 2 process, many Lean techniques have been incorporated
into the design but the real focus of this step it to institute continuous flow of
the product through the process, and to make the process statistically stable.
Other Lean techniques that are focused on usually include:
i. Flow
ii. Jidoka
iii. 5S
iv. Takt time
v. Usually only minor kanban implementation, such as carts, and so on
vi. Balanced operations
vii. Transparency
viii. Standard work
ix. Kaizen
x. 5 Whys
c. Key process and product variables monitored include production rate,
stratified defects, machine availability, First Time Yield, and OEE.
3. Level 3
a. A Level 3 process has all the characteristics of a Level 2 process, plus the
quality levels are understood and are acceptable to the needs of the customer—
in other words, all process steps have adequate Cpks. A continuous quality
improvement effort is in place. Specifically:
i. A modified Part Number Control Plan that addresses the quality issues
found.
ii. Specific measures of internal quality, with long-term graphs available
on the shop floor.
iii. Specific measures of external quality, with long-term graphs available
on the shop floor.
iv. A documented plan of continuous improvement for quality, for both
internal and external quality measures.
v. Continuous improvement quality goals in place, for both internal and
external quality measures.
b. Lean techniques that can now mature at this phase, include:
i. More kanbans
ii. Minimum lot sizes
iii. SMED/OTS