ZERO DELIVERY FAILURE
In the zero delivery process, we possess zero delivery defects in the entire process with the help of different tools that showcase the outcomes of minimum delivery failures. Analyzing the prior activity before any failures or loss in inventory time, WIP storage, lead time, could affect the entire process. Like, if you’re not receiving shipments as quickly as you should, you won’t be able to serve your customers as well as you could and you’ll lose revenue in the process. Factors that can impact lead time include lack of raw materials, breakdown of transportation, labor shortages, natural disasters, and human errors.
Different tools used to identify the failure in the delivery process :
1) Value Stream Mapping
2) Value Supply Chain Management
3) Inventory Analysis & Management
4) Process Mapping (BPM/BPR)
FRAMEWORK FOR ZERO DELIVERY FAILURE PROCESS
1) Involve the team and identify the stakeholders
2) Document as much information as possible when studying the process
3) Keep the flowchart as simple as possible
4) Be careful when making assumptions
5) Use the software/fish-bone diagram to draw the flowchart
6) Start with the end (Goal) in mind
There are many factors synchronized with the manufacturing process like man, material, methods, and machinery along with customer satisfaction. All of these functions essentially feed the core process of production scheduling with the goal of delivering to customers what they need, when they need it. We can analyze to eliminate production waste to improve delivery performance while increasing productivity, inventory turns, and profit.
MANUFACTURING EXCELLENCE IMPLEMENTATION PROCESS
OBJECTIVE :
Zero Delivery / Failure: To accomplish the task within the lead time without failure in inventory time, WIP storage, logistics cost, and mapping of the steps a company takes to complete a certain process.
EXAMPLES :
- Value Stream Mapping
- Value Supply Chain Management
- Inventory Analysis & Management
- Process Mapping (BPM/BPR)
OBJECTIVE :
- 100% Employee Engagement
EXAMPLES :
- Basic 5S Awareness
- 1S, 2S Implementation
- Workplace Visual Management (Visual Factory)
- Kaizen Strategy Implementation
- Suggestion Scheme
- Innovative Leaders
OBJECTIVE :
- Zero Breakdown
EXAMPLES :
- My Machine Campaign
- CLIT
- Machine Utilization Monitoring
- Machine Losses Reduction
- Breakdown Analysis
- Preventive Maintenance
- 3S ,4S & 5S for Machine & Office area
OBJECTIVE :
- Zero Waste
EXAMPLES :
- Time & Motion Study
- Lean Layouting
- ZCA (Zero Cost Automation) & LCA (Low-Cost Automation)
- Material Handling Optimization
- OEE/ OLE
OBJECTIVE :
Zero Accident: The risk of falling, risks related to electricity or handling of machinery, road hazards, and more. Every day, the awareness of each and every employee is essential to avoid accidents in the workplace and to prevent occupational illnesses.
EXAMPLES :
- OH & S Management System Implementation
- Safety KPIs
- Workplace & Safety
- HIRA
- Safety Signage Standardization
OBJECTIVE :
Zero Fatigue: Fatigue is a workplace hazard and can be associated with the safety and health of the worker. It affects the health and safety of the employee.
EXAMPLES :
- Scope Defining
- Workplace Ergonomics Analysis different Technical Score (REBA, RULA, WAS, HARM, NIOSH, JSI, KIM, EAWS, RAMP)
- OFI(Opportunities of Improvements) Points Sharing
- Support in Workplace Design Modification
- Final Audit
OBJECTIVE :
- Zero Effect
EXAMPLES :
- Environment Policy
- Effect Impact Analysis & Life Cycle Assessment
- Energy Cost Optimisation
- Waste Management & Control
OBJECTIVE :
- Zero Defect
EXAMPLES :
- Quality Management System Awareness
- Quality Performance (Quality KPI Development & Tracking )
- Non-Conformities Identification & CAPA Implementation
- Workplace Audit
- 7 QC Tools & 7 Management Tools
- Problem Solving & Poka Yoke
- Root Cause Analysis
OBJECTIVE :
- Zero Loss
EXAMPLES :
- Advance Lean Practices Implementation
- Manpower Rationalization
- Design & Process FMEA
- APQP
- Line Balancing
OBJECTIVE :
- 100% Sustenance
EXAMPLES :
- Employee Training & Re-Training
- DOJO Set-up
- Training Content