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FLV&ICSPSDeploymentDept.page1SPSAssessmenttrainingG&I/IndustrialDeploymentSchneiderProductionSystemSPSAssessmentTraining(FLV&IC)FLV&ICSPSDeploymentDept.page2SPSAssessmenttrainingIcons&meaningsExplanationCheckingpointGoodexampleBadexampleQuestionFLV&ICSPSDeploymentDept.page3SPSAssessmenttraining1SIMPRODUCTION4PROCESSARCHITECTURE/LEANDESIGN8PRODUCTIONPLANNING&SCHEDULING1AWorkInstructions4AManufacturingTimeDefinition8AMasterProductionScheduling1BShortIntervalProduction&QualityTracking4A'ManufacturingTimeDefinition(autoworkshop/line)8BCDO/OFOProcess1CSIMProductionImplementation4BProcessDesign/LeanConcept8B'QueueManagement2SIMSUPPORTFUNCTION4DLateDifferentiation/Adaptation8CInventorymanagement2ASIMSupportFunctionsImplementation5ERGONOMICS/ENVIRONMENT-BAT9PULLPRODUCTION2BSIMSupportFunctionsEfficiency5ABErgonomics/Workstation9ASinglePointScheduling/Pullsystem2CSuggestionSystem/NeedsExpressionBoard5CEnvironment-BAT9BSinglePieceFlowAssembly/WIPManagement3CONTINUOUSIMPROVEMENTinpeoplecommitment5DSafety9CKANBANMethodology3AOperatorFlexibilty6MATERIALHANDLING9DValueStreamManagement3BVersatility&MultiskillsTraining6AReception/WarehouseArchitecture10SUPPLYCHAIN&QUALITYMANAGEMENT3C5S6BMPAHMaterialProvidingandHandlingInternal10ASupplierQualityManagement3DVisualManagement/CommunicatonBoards6CWaterSpider10BSupplyChain(upstream)Management7CONTINUOUSIMPROVEMENTinprocessengineering10CDownStreamSupplyChainManagement7APoka-Yoke10DSharedQualityManagement7BChangeoverTimeMinimization10ECustomerFocus7CLeanSixSigmaKaizen(See/Do)7DTotalProductiveMaintenance7EProcessControl(Part-Product)PEOPLECOMMITMENTPRODUCT/PROCESSENGINEERINGMANAGEMENTOFMANUFACTURING&LOGISTICALPROCESSESIntroduction:3Domains,10Categories,38LinesFLV&ICSPSDeploymentDept.page4SPSAssessmenttraining1–SPSNotion1.Workinstructionsexistfor:a.Manufacturing.b.Quality.Standardworkhasbeendefinedforeachstation2.WorkinstructionsforSafety(basedonriskanalysis)areposted.(instructionboard/workstation).Safetyinstructioncouldbecombinedwithotherworkinstructions,itmustbeposted(forcriticalmachines/stations)Observewhethertheoperatorrespectsthesafetyinstructions2–SPSBasic3.OperatorsweretrainedusingtheworkinstructionsAskthetrainershowtheyfulfillthetrainingtasksCheckwiththeoperators4.Operatorsunderstandtheworkinstructions:a.Safetyb.Qualityc.ManufacturingThese3kindsofinstructionsshouldbepostedontheworkstationsAsktheoperatorswhethertheyknowthedifferentworkInstructionsdotheyunderstandthemeaningsoftheworkInstructionsPeopleCommitment-SIMProduction1a-WorkInstructions-P1-QFLV&ICSPSDeploymentDept.page5SPSAssessmenttraining3–SPSStandard5.WorkinstructionsarevisualWorkinstructionsareeasytobeunderstood,Avoidlongsentence,withfavordrawings/chart,colorfulpictures…Acceptancecriteriasareclearlydefined.6.Workstationinstructionsalsoincludemaintenanceinformationandchangeoverinformation(ifapplicable)Twofilesareconcerned:procedureofvariantchanging&maintenancechecklist(withthetaskandfrequency)TheyshouldbepostedininstructionbookintheU-cell7.WorkInstructionsarerespected(followed)Observethemotionoftheoperatorandcheckwiththeinstructions4–SPSAdvanced8.Thereisastandardprocess,knownbytheoperator,tofollowwhenadefectisdetected(mayincludesignaldevice,empowermenttostoptheline,calltheSupervisor)DecisionmakingprocedureshouldbeavailableforoperatoratcelllevelCheckwithoperatorsPeopleCommitment-SIMProduction1a-WorkInstructions-P1-QFLV&ICSPSDeploymentDept.page6SPSAssessmenttrainingFocuson:WorkInstructionsavailableatworkstation/cell/sectorKeypoints:5mainWorkInstructions(inorderofpriority)Safety(forcriticalmachine/stations)Quality,ProcessflowchartwithQualitycheckpoint.Operations/LineDrivingPreventiveMaintenance/Maintenance(forcriticalmachine/stations)ChangeOver&Managementinstructions(versatilitychart,5S…)WhyweneedWorkInstructions?TotrainoperatorsTochecktheoperatorsonthemainrulestofollow,especiallySafety&QualityTounderstandtheGlobalProcess(Flow-Chart)WorkInstructionsmustbeKnown&respectedSimpleandVisual:canbeseenattheworkstation,avoidlongsentences,usefavordrawing,easytounderstandandacceptancecriteria'sareclearlydefined.KeepUpdatedAuditinworkshopPeopleCommitment-SIMProduction1a-WorkInstructions-P1-Q1-SPSNotion2-SPSBasic3-SPSStandard4-SPSAdvanced5-SPSExpert1.Workinstructionsexistfor:a.Manufacturing.b.Quality2.WorkinstructionsforSafety(basedonriskanalysis)areposted.(instructionboard/workstation).4.Operatorsunderstandtheworkinstructionsa.Safetyb.Qualityc.Manufacturing8.Thereisastandardprocess,knownbytheoperator,tofollowwhenadefectisdetected(mayincludesignaldevice,empowermenttostoptheline,calltheSupervisor)5.Workinstructionsarevisual9.Operatorsareroutinelyparticipatingindeterminationofnewstandardizedworkanddefinitionofworkinstructions10.Workinstructionsare100%visual7.WorkInstructionsarerespected(followed)3.Operatorsweretrainedusingtheworkinstructions11.Workinstructionsarecontinuouslyimproved6.Workstationinstructionsalsoincludemaintenanceinformationandchangeoverinformation(ifapplicable)FLV&ICSPSDeploymentDe