- Details
- Category: DAK Academy Support
The Scale Up Road Map
This second support programme builds on the progress made to date through the Breakout Road map to lock in the gains and support task transfer. That releases specialist resource and management time from dealing with day to day issues to carry out higher value adding activities.
That is equivelent to meeting the challenge of draining the swamp whilst fending off the crocodiles.
Even where the capacity gains cannot be easily converted into output, these countermeasures reduce the risk of human error and levels of quality defects. They also speed up skill development and improve workforce flexibility.
TPM Centre of Excellence Part 2
The Scale up Roadmap involves stakeholders working together to surface and deal with the underpinning causes of capacity constraints. That enhances the Centre of Excellence capabilities by making progress from ad hoc problem solving to focussed improvement. Find out more here.
That includes better use of data to develop a deeper understanding of cause/effects and to develop competencies to support improved flow and capacity.
Support Plan Structure
1: TAKE STOCK AND ENCOURAGING NEW THINKING.
- Readiness Review: Assess strengths, weaknesses, improvement potential and develop recommended next steps
- Plan the plan: Develop forward workplace learning projects
2: RAISE PERFORMANCE AND RELEASE POTENTIAL
- Training Workshop: The glide path to optimum conditions
- Core Team Sessions: Identify problem hot spots
- Review/refine asset care
- Review/refine operating standards
- Improve design weaknesses
- Prevent mis operation
- Prevent repair errors
3: BUILD CAPABILITY AND ENGAGEMENT
- Mid project review, policy development and forward planning
- Standardise core skills for normal conditions
- Reduce unplanned adjustments
- Systemise planned adjustments
4: DELIVER THE FULL POTENTIAL
- Capture lessons learned as Policy Standads and roll out to other areas.
Support Plan Example
Below is an example of how to develop capabilities to ratchet up effectiveness using a practical improvement project around a key asset. (Follow the links for more details of individual courses.)
A. Diagnostic and Plan the Plan Session:
Reliability for Manufacturing Leaders
This 2 hour on-line awareness workshop provides an insight into how award winning and well respected organisations are able to systematically deliver reliable, stable operations.
Learn how to counter the traditional pressures on output and break out of the reactive manufacturing environment where there is no time to deal with the root causes of unplanned downtime even when they are understood
B. Mobilisation Training Workshops:
TPM Best Practice Implementation
Format: 3 Day hands on training workshop
Learn how to implement Total Productive Manufacturing principles and techniques to release the full potential of your people, procedures and work processes.
Turn theory into practice during the workshop by applying theory to assets on the factory floor using a comprehensive TPM application workbook.
C. Implementation Support:
Format: Online 4 sessions
First Line and Mini Business Leaders are at the heart of any organisations ability to deliver value to customers. They are the ones who can make an organisation run like clockwork. As customer expectations ratchet up and the pace of technology accelerates, their role is evolving. This training workshop will provide participants with a road map to equip First Line leaders with the knowledge and skills to drive practical changes through their teams.
Front Line Skill Development Best Practice
Format: 2 Day in house training workshop
The course content covers best practices for
- Role and task design
- Including the use of standards to accelerate learning
- Balancing team skill profiles
- Including issue response and resolution
- Asset and individual learning plans
- Training and compliance feedback
- Including methods improvement and standardisation
- Work instruction ownership and review
The course includes a systematic review of existing processes and work routines to surface barriers and identify actions to resolve them.
Take Control
The scale up road map sets out the steps to standardise work routines and speed up skill development processes through actions to:
- Simplify critical and complex processes so that they are easy to do right, difficult to do wrong and simple to learn.
- Standardise core tasks to improve workforce flexibility and use of skills.
- Make normal conditions visible at a glance to improve early problem detection
That is underpinned by the development of effective shop floor processes and Front Line Leader skill skills to engage front line teams with practical actions to create:
1. A Plan for Every Asset (PFEA) to support the continuous update of working methods, standard practices and learning plans so that changes are controlled and work standards are maintained.
2. A Standardisation process covering Learning plans and pathways to structure the building blocks of capability development, employee engagement and high performance teamwork.
3. Local Area performance management processes that drive improvement in work practices, standards and skills as part of the day to day routine.
4. A Focussed Improvement glide path and tactics to systematically raise effectiveness.
Contact us for more information or to arrange a call to discuss how we can support your Scale Up Road Map programme.
Get Better
Business Leader Development Modules
|
Who |
Task |
Training Content |
|
Business Sponsor, Support specialists, CI Manager |
Make continuous improvement a part of everyone’s day job. Set improvement challenges to trigger new thinking about business improvement priorities. |
Scale up road map milestones, Gap analysis and Improvement policy deployment. |
Departmental Leader Development Modules
|
Who |
Task |
Training Content |
|
Departmental Head |
Value hidden losses and wastes in financial terms Coach and mentor as part of the daily management process. |
Implementation roles and implementation route map and coaching to establish better working practices. |
|
Team Leaders |
Visual management standards for flow coordination and adherence to best practice. |
Front line skill development process covering task design, standardisation, learning plans and compliance management. |
|
Engineering specialists and Trainers |
How to identify technology issues and their cause/effect mechanisms. |
Personal planning, mapping action plans, managing improvement activities and conditioning new working practices. |
|
Planners and Administrators |
Integrate the skill development activities as part of the routine work plan. |
Setting team goals, evaluating progress against planned outcomes. |
Front Line Team Development Modules
|
Who |
Task |
Content |
|
Front Line Team Members |
Improve reliability and extend asset life. Manage normal conditions. Deliver operational (low cost or no cost) improvements. |
See below: |
|
F1 |
Stabilising asset performance. |
Criticality analysis, establish condition standards and core asset care routines. |
|
F2 |
Setting asset improvement priorities/tactics. |
Define trouble map, issue prioritisation and local asset improvement tactics. |
|
F3 |
Mapping asset capability. |
Analysing equipment/process capability and raising standards |
|
F4 |
Problem hot spot improvement. |
Surface technology blind spots, systemise response and removal of causal factors. |
|
F5 |
Learning from sporadic losses. |
Deal with accelerated wear and causes of human error |
|
F6 |
Problem observation and root cause analysis |
How to recognise patterns of failure and make "Normal conditions" visible to all. |
|
F7 |
Problem prevention. |
Workplace organisation, best practice procedure design and implementation. |
|
F8 |
Visual Management. |
Visual management steps 1 to 4, Foolproofing and problem prevention. |
|
F9 |
Targeting waste and hidden losses. |
Use of OEE and Flow as leading indicators, understanding root causes and systematic improvement in waste and hidden losses reduction. |
