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Bundaberg Brewed DrinksHome Brew Program
Module 8
Advanced Systems & Processes
Russell Cummings
Agenda
• Business Excellence Model
• FMEA
• Next Steps
Home Brew Program 2009
Advanced Systems & Processes Tools
Business Excellence Model
Failure Mode Effect Analysis
FMEA
LEADERSHIP10%
PEOPLEMANAGEMENT
9%
POLICY &STRATEGY
8%
RESOURCES & PARTNERSHIP
9%
PROCESSES14%
CUSTOMERSATISFACTION
20%
PEOPLESATISFACTION
9%
IMPACT ONSOCIETY &
ENVIRONMENT6%
KEY PERFORMANCE15%
• Focuses on outcomes and processes.
• Enables self-assessment.
• Applicable to a wide range of industries.
• Supports a culture of continuous improvement.
Enablers 50%
Results 50%
BUSINESS EXCELLENCE MODEL
Exercise
What would we need to understand to measure each component? How will you measure this?
• Leadership• People Management• Policy & Strategy• Resources & Partnerships• Processes• Customer Satisfaction• People Satisfaction• Impact on Society & Environment
Click on pause to stop the DVD.
Press Play to start DVD again when you have finished the exercise
Home Brew Program 2009
Scoring the Business
Home Brew Program 2009
ExerciseElement Score Now Where Gap
Leadership 10
People Management 9
Policy & Strategy 8
Resources & Partnerships
9
Processes 14
Customer Satisfaction
20
People Satisfaction 9
Society & Environ. 6
Key Performance 15
TOTAL 100
Home Brew Program 2009
Score BBD from your perspective
against the Excellence Model.
1.Score the NOW.2.Score WHERE BBD needs to be3.Calculate the
Gaps4.Develop Action
Plans to address the Gaps
Click to pause DVDClick Play to start again.
Managing Risk
Failure Mode Effect Analysis
FMEA
Home Brew Program 2009
Risk
• As managers at BBD, you assess and manage risk everyday
• Rarely do we assess risk using objective methodologies (safety and quality audits)
• We can apply a structured process to assessing risks - FMEA
• Failure Mode Effect Analysis
Home Brew Program 2009
10 Step FMEA
Step 1: Agree the product, service, entity or process under review
Step 2: Clearly define the core functions of the entity under review (optional for larger entities)
Step 3: Identify potential failure modes (brainstorm and group)
Step 4: List the potential Failures?
Step 5: What are the effects of each failure?
Step 6: What are the causes of each failure?
Home Brew Program 2009
10 Step FMEA
Step 7: What are the current controls and/or detection methods?
Step 8: Rate the following:– Severity - the consequences of the failure should it occur.
– Occurrence - the probability or frequency of the failure occurring.
– Detection - the probability of the failure being detected before the impact of the effect is realized.
Step 9: Calculate the Risk Priority Number
Step 10: Develop Actions to address top risks
Home Brew Program 2009
Failures Rankings Potential Mode Or Failure
Potential Effects Of Failure
Potential Causes Of Failure
Current Controls/ Detection Methods
Severity (A) 1 = non 3 = slight 5 = moderate 7 = major 9 = serious 10 = hazard
Occurrence (B) 1 = never 3 = very slight 5 = low 7 = mod high 9 = very high 10 = almost certain
Detection (C) 1 = certain 3 = high 5 = medium 7 = slight 9 = remote 10 = almost impossible
Risk Priority Number (RPN)
(A)x(B)x(C)
Signal Loss Unstable Control loop
Faulty Leads Operator 9 5 4 180
Endanger operators
Serious damage
Defects in products
Customers complain
Incorrect Motion
Visual check 4 5 5 100
Faulty products identified
Product/Process/Service: MotorFunction: Provides Voltage Signal and is responsible for final productDate: 24 Oct 06 FMEA prepared by: A. Ameroth FMEA revision date: 8 Jan 07
1. Signal Loss Durability test on leads Who and When By 2. Defects in Products Increase in staff inspection QC checked Set up customer complaint
department.
FAILURE MODE EFFECT ANALYSIS (FMEA)
FMEA Exercise
Complete a Risk Analysis of an area of the business that you are responsible for. Apply the FMEA tool and develop actions to address key areas of risk.
Click on pause to stop the DVD.
Press Play to start DVD again when you have finished the exercise
Home Brew Program 2009
Next Steps
Complete any outstanding exercises
Tools & Templates
Use the Home Brew Site as a reference source
Use the DVDs for review of any particular areas
Home Brew Program 2009
Thanks
Strategy into Action
Home Brew Program 2009
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