Page 73 - MODULE QUALITY TOOLS DMQ 30262

DMQ 30262

EXPLOIT:

(CAUSES)
 Was using false productivity numbers based on operator up-time
 Had no scoreboards for posting results

 No method for assuring sufficient machine availability

(CURES)
 Change measurement to 100% utilization based
 Create daily and monthly scoreboards for operators and entire shift

 Developed form for "machine availability" assurance

SUBORDINATE:

 Production scheduling started reporting shots per hour based on 24 hours/day in lieu
of "up-time"

 Process engineering developed a daily spreadsheet which documented shots per
hour and posted daily for all three shifts
 Die cast department established benchmark and goals for 2000, 2001 and 2002,

conducted shift-wide brainstorming sessions for improvement actions
 Support departments agreed to increase labour when needed to support machine
availability

ELEVATE: Removed "special" causes of individual shift constraints, increased overall
throughput by 27%.

INERTIA: (CELEBRATE) Named "Through-Put Improvement Team" as the team of the year,
furnished prizes for each quarter over goal and most importantly, we are making more

money now and in the future.

KKTM Kuantan 72 DMQ 30262