Fundamentals of Daily Shop Floor Management: A Guide for Manufacturing Optimization and Excellence

363 Pages·2022·9.921 MB·English

by  Philip J. Gisi

Fundamentals of Daily Shop Floor
Management
Survival and thriving in today’s business environment require companies to continu-
ously strive for operational excellence at all levels of the organization. Simply working
to maintain existing operations is not an adequate or sustainable business strategy,
especially when competing in a global market. To remain relevant, companies must
adopt a process control and continuous improvement mentality as an integral part of
their daily work activities. These two operational disciplines form the foundation and
stepping stones for manufacturing excellence. Processes must be stable, capable, and
controlled as a prerequisite for sustainable improvement. Sustainable improvements
must be strategic, continuous, and focused on process optimization.
Modern- day manufacturing is rapidly changing in the face of technological,
geopolitical, social, and environmental developments. These challenges are altering
the way we think and act to transform raw materials into finished goods. Meeting
these challenges requires particular attention to how we develop and engage people
and apply technology for long-t erm sustainability and competitive advantage. This
book takes you on a journey to explore the fundamental elements, management
practices, improvement methods, and future direction of shop floor management.
Part 1 of this five-p art manuscript considers workplace culture, organizational
structure, operational discipline, and employee accountability as the foundation for
a robust manufacturing system. Part 2 studies the impact of process standardization,
data analytics, information sharing, communication, and people on daily shop floor
management. Once the management system has been adequately described, Part 3
concentrates on its effective execution, monitoring, and control with a deep look into
the people, methods, machines, materials, and environment that make it possible.
Like every good manufacturing text, efficiency and productivity are key topics. That’s
why Part 4 explores various methods, tools, and techniques associated with prod-
uct and process development, productivity improvement, agile methods, shop floor
optimization, and manufacturing excellence. The final section, Part 5, shifts focus to
emerging technologies, engaging the reader to contemplate technology’s impact on
the digital transformation of the manufacturing industry.

Fundamentals of Daily Shop
Floor Management
A Guide for Manufacturing Optimization
and Excellence
Philip J. Gisi
First Published 2023
by Routledge
605 Third Avenue, New York, NY 10158
and by Routledge
4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
Routledge is an imprint of the Taylor & Francis Group, an informa business
© 2023 Philip J. Gisi
The right of Philip J. Gisi to be identified as author of this work has been asserted by them in
accordance with sections 77 and 78 of the Copyright, Designs and Patents Act 1988.
All rights reserved. No part of this book may be reprinted or reproduced or utilized in any form
or by any electronic, mechanical, or other means, now known or hereafter invented, including
photocopying and recording, or in any information storage or retrieval system, without permis-
sion in writing from the publishers.
Trademark notice: Product or corporate names may be trademarks or registered trademarks, and
are used only for identification and explanation without intent to infringe.
ISBN: 978-1-032-37055-2 (hbk)
ISBN: 978-1-032-37054-5 (pbk)
ISBN: 978-1-003-33509-2 (ebk)
DOI: 10.4324/b23307
Typeset in Garamond
by SPi Technologies India Pvt Ltd (Straive)
Contents
Preface ........................................................................................................................xv
Acknowledgment .....................................................................................................xix
About the Author .....................................................................................................xxi
Introduction .................................................................................................xxiii
Overview ..........................................................................................................xxiii
Book Contents ..................................................................................................xxv
Part 1: Shop Floor Foundation .....................................................................xxv
Part 2: Shop Floor Fundamentals ...............................................................xxvi
Part 3: Shop Floor Management .................................................................xxvi
Part 4: Shop Floor Improvement ...............................................................xxvii
Part 5: Next-Generation Shop Floor ..........................................................xxvii
The Journey to Manufacturing Excellence .....................................................xxvii
Daily Shop Floor Management .......................................................................xxix
Essential Practices of Shop Floor Management ...............................................xxx
Summary ........................................................................................................xxxiii
Key Points ......................................................................................................xxxiv
A Note about Supply Chain Management (SCM) .........................................xxxiv
Manufacturing Supply Chain Management ....................................................xxxv
Administration ...............................................................................................xxxvi
Production (e.g. Manufacturing) ..............................................................xxxvii
Distribution ................................................................................................xxxix
Source ............................................................................................................xxxix
PART I SHOP FLOOR FOUNDATION
Overview ...............................................................................................................1
1.1 Organizational Culture ...............................................................................5
Introduction ..........................................................................................................5
Lean Mindset and Culture ....................................................................................6
Organizational Commitment ................................................................................7
Organizational Alignment ....................................................................................9
Source .................................................................................................................11
v
vi ◾ Contents
1.2 Organizational Structure ..........................................................................13
Overview .............................................................................................................13
Organizational Framework .................................................................................15
Business Strategy............................................................................................16
Guiding Principles ..........................................................................................17
Routine Practices ............................................................................................17
Shop Floor Management Planning ................................................................18
Manufacturing Operations Manual ................................................................19
Guidelines, Procedures, and Standards .........................................................20
Shop Floor System Execution ............................................................................21
Standard Work Routines .................................................................................21
Shop Floor System Monitoring ..........................................................................23
Key Process Indicators ...................................................................................24
Visual Controls ...............................................................................................24
Gemba Walks ..................................................................................................24
Performance Reviews .....................................................................................25
Layered Process Audits ..................................................................................25
Process Control ...................................................................................................25
Deviation Management ..................................................................................25
Action Item List ..............................................................................................25
Structured Problem-Solving ...........................................................................26
Total Productive Maintenance ........................................................................26
Productivity Improvement..................................................................................26
Key Points ...........................................................................................................27
1.3 Operational Discipline .............................................................................29
Overview .............................................................................................................29
Sustainable Discipline ........................................................................................31
Improving Operational Discipline .....................................................................32
How to Maintain Operational Discipline ...........................................................33
Key Points ...........................................................................................................34
Source .................................................................................................................35
1.4 Employee Accountability ..........................................................................37
Overview .............................................................................................................37
Corporate Accountability ....................................................................................38
Employee Accountability ....................................................................................39
Peer Accountability .............................................................................................40
Shop Floor Accountability ..................................................................................40
Setting Employee Expectations ..........................................................................41
Employee Feedback .......................................................................................42
Employee Empowerment ...............................................................................42
Rewards and Consequences ...........................................................................42
Treat People with Respect .............................................................................42
Communication ..............................................................................................43
Strategy Alignment .........................................................................................43
Accountability vs. Micro-Management ...............................................................44
Contents ◾ vii
Attitude, Behavior, and Accountability ..............................................................44
Commitment and Accountability ........................................................................45
Key Points ...........................................................................................................45
PART II SHOP FLOOR FUNDAMENTALS
Overview .............................................................................................................49
2.1 Standardization ........................................................................................51
Introduction ........................................................................................................52
Workplace Cleanliness and Organization (5S) ..................................................54
Standard Procedures and Work Instructions .....................................................54
Standard Operation Sheet ..................................................................................56
Workplace Design ..............................................................................................56
Key Points ...........................................................................................................58
2.2 Shop Floor Data and Information ............................................................59
Measurement Data ..............................................................................................60
Key Process Indicators .......................................................................................60
Data Gathering ...................................................................................................63
Data Analysis ......................................................................................................64
Data Reporting ...................................................................................................66
Key Points ...........................................................................................................66
2.3 Data Visualization ....................................................................................67
Overview .............................................................................................................68
Visual Controls for Process Management ..........................................................68
Common Visual Control Displays ......................................................................70
Information or Communication Boards .........................................................70
Manpower Planning Boards ...........................................................................71
Employee Cross-Training or Qualification Matrix .............................................71
Andon Boards and Lights ...................................................................................75
Display Chart Preparation Tips ..........................................................................75
Key Points ...........................................................................................................76
2.4 Shop Floor Communication .....................................................................77
Overview .............................................................................................................78
Machine to Machine (M2M) Communication ....................................................78
Machine to Business (M2B) or Machine to Enterprise (M2E)
Communication ..................................................................................................79
Shop Floor Communication ...............................................................................79
Daily Meetings ................................................................................................80
Weekly Meetings ............................................................................................80
Monthly Meetings ...........................................................................................81
Project Performance Reviews .........................................................................82
Gemba Walks ..................................................................................................82
Mobile Devices ...................................................................................................83
Key Points ...........................................................................................................84
viii ◾ Contents
2.5 Shop Floor People....................................................................................85
Overview .............................................................................................................86
Employee Empowerment ...................................................................................86
Respect, Honesty, and Trust ...............................................................................88
Training and Development ................................................................................89
Mentoring and Coaching ....................................................................................91
Recognition and Reward ....................................................................................91
Stakeholder Management ...................................................................................92
Key Points ...........................................................................................................93
2.6 Facilities Management .............................................................................95
Shop Floor Environment ....................................................................................96
Technical Cleanliness .........................................................................................96
Ergonomics .........................................................................................................96
Electrostatic Discharge .......................................................................................98
Utilities ................................................................................................................98
Key Points ...........................................................................................................99
Source .................................................................................................................99
PART III SHOP FLOOR MANAGEMENT
Overview ...........................................................................................................101
Key Points .........................................................................................................103
3.1 Manufacturing System Execution ..........................................................105
Overview ...........................................................................................................105
Standard Work Routines ...................................................................................106
Preparing Standard Work Routines ..................................................................108
Key Points .........................................................................................................110
3.2 Manufacturing System Monitoring ........................................................111
Overview ...........................................................................................................112
Process Monitoring/Verification .......................................................................113
Go, See, Observe ..............................................................................................113
Gemba (Management) Walks ...........................................................................114
Scrap Walks/Reviews ........................................................................................117
Layered Process Audits .....................................................................................118
Performance Reviews .......................................................................................120
Key Points .........................................................................................................121
3.3 Manufacturing System Control ..............................................................123
Overview ...........................................................................................................123
Manufacturing System Control .........................................................................124
Process Control .................................................................................................125
Manufacturing System Integrity .......................................................................126
Standard Work Routines ...................................................................................127
Deviation Management ....................................................................................128
Deviation Management Tips.............................................................................129
Contents ◾ ix
Structured Problem-Solving .............................................................................129
Action Items ......................................................................................................131
Decision-Making ...............................................................................................133
Poka-Yoke (Error Proofing) ..............................................................................133
Jidoka ................................................................................................................134
Change Management ........................................................................................135
Production Change Points ................................................................................136
Bottleneck Management ...................................................................................136
Additional Manufacturing System Controls .....................................................137
Key Points .........................................................................................................138
3.4 Manpower ..............................................................................................141
Overview ...........................................................................................................141
People Availability ............................................................................................142
People Flexibility ..............................................................................................142
Workload Balancing .........................................................................................142
Manufacturing Gauges and Tools ....................................................................143
Employee Motivation ........................................................................................143
Training and Experience ..................................................................................143
Workplace Design and Ergonomics .................................................................143
Working Conditions (Environment) .................................................................144
Autonomous Maintenance ................................................................................144
Labor Efficiency ................................................................................................145
Employee Safety ...............................................................................................145
Key Points .........................................................................................................146
Source ...............................................................................................................147
3.5 Material ..................................................................................................149
Overview ...........................................................................................................149
Material Requirements Planning ......................................................................151
Material Deployment and Replenishment .......................................................151
Milk Run ...........................................................................................................152
Water Spiders ....................................................................................................152
Material Handling and Storage ........................................................................153
Traceability .......................................................................................................154
Inventory Management ....................................................................................154
Health and Safety .............................................................................................156
Key Points .........................................................................................................157
Sources ..............................................................................................................157
3.6 Manufacturing Equipment, Fixtures, and Tooling ..................................159
Overview ...........................................................................................................159
Equipment Optimization (Effectiveness, Reliability, and Durability) ..............160
Overall Equipment Effectiveness .....................................................................160
Efficiency Losses...........................................................................................161
OEE Calculation............................................................................................162
OEE Improvement Cycle (with Plan-Do-Check-Act [PDCA]) ......................164