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At the recent Manufacturing Technology 2008 Exhibition, Professor Dennis McKeag of the School of Electrical & Mechanical Engineering, University of Ulster, delivered a highly stimulating presentation on the practical implementation of the mangement philosophies: Kaizen, Six Sigma and Lean Manufacturing. Through case study examples, with plenty of personal anecdotes thrown in, Professor McKeag illuminated these familiar but often misunderstood management philosophies.

Further to the presentation, Professor McKeag offered a suggested introductory reading list:

 

Six Sigma for Everyone; George Eckes; Wiley; ISBN 0-471-28156-5

Approximately: Stg£11.00

A short, easy to read book based on 6-sigma using Kaizen principles that can be equally applied to Lean. Perhaps the best place to start.

 

Gemba Kaizen – A commonsense low-cost approach to management; Masaaki Imai; McGraw-Hill; ISBN 0-07-031446-2

Approximately: Stg£20.00

Based on organising and managing the workplace. The key techniques of 5S, MUDA and Visual Management are very well covered. Good for anyone wanting to manage the shop-floor and quite easy to read.

 

Six Sigma – The Breakthrough Strategy Revolutionizing The World’s Top Corporations; Mikel Harry and Richard Schroeder; Currency; ISBN 0-385-49437-8

Approximately: Stg£25.00

Good for Six Sigma implementation. The complete Six Sigma philosophy in an easy to read format. Best suited to repetitive activities such as those found in offices, for example sales order processing, accounts etc.

 

The Lean Six Sigma Pocket Toolbox;  Michael L George, David Rowlands, Mark Price, John Maxey; McGraw-Hill; ISBN 0-07-1441190-0

Approximately: Stg£12.00

As the name implies, a large number of Lean/Six-Sigma/Kaizen tools. You are likely to find your preferred techniques here. If you find a technique here there is enough information to begin to use it, but you may want to follow up with some specific and more detailed reading on the technique.

 

Learning to See – value stream mapping to add value and eliminate muda; Mike Rother & John Shook; The Lean Enterprise Institute; ISBN 0-9667843-0-8

Approximately: Stg£20.00

Value stream mapping of product and information flow is the best start point for any initiative and this is the best book to use for VSM.

 

OEE and Lean Manufacturing 6-Sigma, Kaizen, Lean, Lean Manufacture, Six Sigma

 

OEE Loss (by Object) Shift Report with Pie Chart

A standard Provideam Loss Report might appear like the example in figure 1 below.

Fig. 1 OEE Loss by Object Report

 

In this report we see a breakdown of the losses for AssemblyMC1 for the Day Shift on the 2nd of October. The losses are displayed both in graphical

and tabular format. The upper table shows a list of the losses sorted in descending order of magnitude of the Time function. The lower table shows a

selected list of functions calculated over the shift. These ‘overall’ functions help to put the loss figures in context.

 

To help us get a perspective on the actually losses we have included the OEE Time in this report (the green pie segment). This is the total time

that the machine was running at its optimum rate. It is a feature of Provideam that you can specify whether to include or exclude categories of loss

on your reports.

 

To create a report like that shown in figure 1 above, follow these steps;

Step 1: Click on the ‘New Report’ icon
Step 2: Select the OEE Loss (Group by Object) option

 

Fig. 2 OEE Loss by Object Report - New OEE Loss Report

Step 3: Click Next to move on to the Area/Machine (Object 1) selection.
Step 4: Select AssemblyMC1 from the list of available Machine items.

 

Fig. 3 OEE Loss by Object Report - Select Object

Step 5: Click Next to move on to name the Object.

By default the Report Wizard enters the Object Description shown below. You may edit this if you wish.

 

Fig. 4 OEE Loss by Object Report - Edit Object Description

Step 6: Click Next to move on to on to the Loss selection.
Step 7: Choose Level 1 Loss and select All from the list of available Level 1 Loss items. This option results in all time, from OEE Time to Planned

Downtime, being included in the Loss Report.
Step 8: Check Show for Level 3 Desc. This results in a breakdown by Level 3 Description on the final report.

 

Fig. 5 OEE Loss by Object Report - Select Loss

Step 9: Click Next to move on to Functions selection.
Step 10: Select Time from the list of available Loss Function items.
Step 11: Select PlannedOpT, UpTime, Downtime, Good Parts and Defect Parts from the list of available Production Function items.
Step 12: Use the Up and Down buttons to order the Functions. They will appear in the final report in the order  you set here.
Step 13: Check the Show Grand Totals checkbox.

 

Fig. 6 OEE Loss by Object Report - Select Functions

Step 14: Click Next to move on to Period selection.
Step 15: Select the Shift period option.

 

Fig. 7 OEE Loss by Object Report - Select Period

Step 16: Click Next to move on to the final screen in the Report Wizard.
Step 17: Select the Pie Chart Graph option.
Step 18: Check the Show Graph option.
Step 19: Click Run Report to run this Report.

You may save the report definition as a Report Template at this stage. Report Templates can be shared with other users and also scheduled for

automatic delivery by email.

 

Fig. 8 OEE Loss by Object Report - Select Graph Style

Step 20: Select a Date and Shift.

 

Fig. 9 OEE Loss by Object Report - Select Report Period Parameters

Step 21: Click Run Report to generate a report preview.

 

Fig. 10 OEE Loss by Object Report - Preview Shift Report
 

Provideam Tips OEE, OEE and Lean Manufacturing, OEE Loss, Overall Equipment Effectiveness