THE PRAGMATIC FMSTRUCTURED - FOCUSED - INTENTIONAL

PURPOSED - TECHNICAL MANAGEMENT

TOPICS – PRACTICAL APPROACH TO IMPROVEMENTS

• Poka-Yoke (Mistake Proofing)

• Kaizen

• 5S

• Lean Six Sigma (Lean Sigma, Lean Manufacturing)

• TQM / 3P

POKA-YOKE

• To avoid (yokeru) - inadvertent errors (poka)

• Japanese - mistake proofing

• Prevents incorrect assembly

• Easily identifies flaws

• Step one of complete error-proofing

• Designed to prevent incorrect performance

POKA-YOKE

• Attempt on the cheap

• Simpler is better

• Not optional

• Information alone is not mistake proofing

• No decision making

THINK OF A FACILITIES EXAMPLE

• What is being done here

• What is the problem

• Could problem be further mistake proofed

WHAT ELSE NEEDS ERROR PROOFING

• Possible problem that can be error proofed in a restroom

• Custodial labor related to restroom cleaning

COMPARE TO FACILITIES EXAMPLE

• What is problem

• How could it be further mistake proofed

• How could you use something like this in facilities (room set-up diagrams)

KAIZEN• Japanese word: Kai = Change Zen=Good

• Continuous Improvement

• Eliminate waste by improving standardized processes

• Going beyond simple productivity improvement

• Performed correctly, the process:

• Humanizes the workplace

• Eliminates overly hard work

• Teaches people how to spot and eliminate waste

KAIZEN

• Identify an opportunity

• Analyze the process

• Develop an optimal solution

• Implement the solution

• Study the results

• Standardize the solution

• Plan for the future

KAIZEN

• Replace conventional fixed ideas with fresh ones.

• Start by questioning current practices and standards.

• Seek the advice of many associates before starting a Kaizen activity.

• Think of how to do something, not why it cannot be done.

• Don’t make excuses. Make execution happen.

• Do not seek perfection. Implement a solution right away, even if it covers only 50 percent of the target.

• Correct something right away if a mistake is made.

KAIZEN

• One day or week long

• Whole team involved

• Stop regular work

• Provide incentive and tools

• Change immediately implemented

• Short but effective at small improvement

• Smaller part of continuous improvement

KAIZEN FACILITIES EXAMPLES FOR FMS

• Every teammate involved / influence

• Provide tools / framework / basic goals

• Give out a reminder to mark change

• Have a Picnic BBQ

• Be satisfied with small improvements

5S• The S’s stand for:

• Seiri or sort

• Seiton or straighten

• Seiso or shine

• Seiketsu or standardize

• Shitsuke or sustain

System - instilling order and cleanliness in the workplace

5S

5S – ALTERNATIVETERMS

• Sorting

• Systematic arrangement

• Spic and span

• Standardize

• Self-discipline

• Put things in order

• Proper arrangement

• Clean

• Purity

• Commitment

Before 5S After 5S

5S Facilities Example:

• Know what is missing • Know what is running

low• Know what is clean• Prevent forgetting a tool• Cleans off the cart• Color Coded for Use• Quicker to Find

LEAN – TENDS TO FOCUS ON SPEED

• Value – from customer view

• Value Steps – eliminate non-value steps

• Flow – tight sequence

• Pull – customer requests

• Perfection – when no waste based on customer

LEAN -PRODUCTION / MANUFACTURING / ENTERPRISE

• Zero waiting time

• Zero Inventory

• Scheduling — internal customer pull instead of push system

• Batch to Flow — cut batch sizes

• Line Balancing

• Cut actual process times

LEAN FACILITIES AREAS OF FOCUS

• Overproduction

• Queues

• Transportation

• Inventory

• Motion

• Over processing

• Defective product

LEAN FACILITIES EXAMPLES FOR FMS

• Electricity Usage

• Room Set-up

• Landscaping

• Custodial Efforts

• Team Uniforms

SIX SIGMA – FOCUS ON QUALITY

• 3.4 defects per million chances

• Increase profits

• Eliminate variables, defects and waste

• Improve customer satisfaction

• Use facts, data and analysis

SIX SIGMA

• Define

• Measure

• Analyze

• Design

• Control / Verify

6 SIGMA – FACILITIES SIMPLIFIED

• Customer Complaint?

• How can you quantify – run a test with data

• Brain storm how to improve it, chose best improvement

• Remeasure with same points - partial process or test process

• Implement improvement on whole process – confirm new data

• Control or Sustain Improvement – verify with data

SIX SIGMA TOOLSDefine Measure Analyze Implement Control

EXAMPLE LEAN SIGMA – EL PASO PARKS AND REC

• Pareto analysis - 70% of all wo’s on heads and valves

• Top solutions:• Implement 5S – standardized stock vans, corrals and warehouse

• Create satellite storage areas - reduce travel time

• Use a groundskeeper as a “runner” working with the material supervisor

• Reassign work area zones to match material / stock locations

• Goal: Reduce the repair time & cost / work order by 33%.

• Results: Reduction by 92%.• Time / irrigation repair work order reduced from 24 hours to only 1.81 hours

• Cost / work order decreased from $297.36 to $22.40, estimated annual cost avoidance of $78,089 in payroll costs

6 SIGMA FACILITIES EXAMPLES

• Work Order Response Time

• Customer Satisfaction Survey Results

• Number of Reworks

• Number of Too Hot Too Cold Calls

• Energy Cost

• Fuel Cost

TQM

• Ethics & Integrity

• Trust

• Leadership

• Teamwork

• Training

• Recognition

• Communication

3P

• People:

• Internal and external

• Product:

• Required specs

• Process:

• Continuous improvement

MULTIPLE DIVERSE COMBINATIONS• Total Lean Six Sigma Integration - with tools

• Diverse

• Complex

• High Level

• Broad

• Long term

CONDENSE / BASIC LESSONS FOR FMS

• Lead - actively engaged

• Thoughtful – use tools

• Others - involve the team

• Real Data / Facts

• Focus – improvements, goal, mission

• Never Quit – closed loop

BIBLICAL LESSONS

• Not growing - then dying

• Include others – Refuse the Credit

• Take a Sabbath – switch gears

• Remember the Past – Similar thing have already been done

• Walk by Faith

DISCUSSION

• How can an FM be pragmatic about improvements?

• Quality, Speed, Customer Satisfaction, Cost

• Which is most important?

• What have you begun?

• Share Successes

REFERENCES

• https://www.isixsigma.com/

• http://texasleansixsigma.com/city-of-el-paso-irrigation-repair/

• http://www.lc-stars.com/people-process-product.html

• https://www.lean.org/

• God’s Word