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| Click here to download a printable copy of our assessment questionnaire. | |
| Manufacturing Flow | |
| 1.
Does material flow in one direction throughout the plant?
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| 2.
Is the manufacturing process designed to have operators touch material
only one time?
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| 3.
Are production areas aligned to end-customer products?
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| 4.
Are work centers designed to meet daily customer requirements?
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| 5.
Is product passed between operations one piece at a time?
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| 6.
Is the flow of production visible and understandable?
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| 7.
Do operators flex between work centers?
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| 8.
Is manufacturing synchronization (value-added time/total mfg. cycle
time) at least .75?
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| Organization
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| 1.
Are flow path leaders held accountable for end-product performance
results?
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| 2.
Are cross-functional teams used on the flow path?
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| 3.
Are the roles/responsibilities for all team members defined and
documented?
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| 4.
Do operators know all steps in the flow process for their areas?
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| 5.
Are support roles clearly defined and involved in flow path efforts?
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| 6.
Is there a systematic two-way communication process?
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| 7.
Is management conducting performance appraisals based on flow performance?
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| 8.
Is compensation linked to performance?
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| Continuous Improvement | |
| 1.
Are changeover times on bottleneck resources less than 10 minutes?
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| 2.
Is there a defined continuous improvement program?
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| 3.
Is response time less than 15 minutes for defects found in the production
process?
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| 4.
Do team members have the authority to stop the flow path when defects
are discovered?
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| 5.
Is the company philosophy "Everything has a place and everything
in its place"?
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| 6.
Are stretch goals included in performance metrics?
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| 7.
Are work instructions and product quality specifications visible
at all work areas?
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| 8.
Are timetables posted for preventative maintenance or continuous
improvement efforts?
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| Metrics
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| 1.
Are performance measures visible and current on the flow path?
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| 2.
Are updated charts on productivity, quality, safety, and problem
solving visible for teams?
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| 3.
Is performance reviewed daily by flow path teams?
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| 4.
Is schedule adherence 100% on time?
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| 5.
Are manufacturing cycle times less than one day?
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| 6.
Is the flow path performance continually improving?
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| 7.
Do flow path work center operators own and report their performance
data?
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| 8.
Are performance metrics linked to financial metrics?
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| Global
Supply Chain
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| 1.
Do production areas build to customer demand?
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| 2.
Is material pulled between stations?
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| 3.
Does the shop floor produce to a daily build schedule?
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| 4.
Is material replenished to an A,B,C segregation?
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| 5.
Are shop floor operation planning rules documented and understood?
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| 6.
Are firm planning cycle times less than one day?
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| 7.
Is a supplier certification process, with measurements, displayed?
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| 8.
Does the daily build plan meet customer and financial commitments?
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