Focused Improvement a column in World Class Manufacturing

Focused Improvement Pillar

In the ever-evolving landscape of manufacturing, achieving excellence is not merely a goal; it's a necessity. Manufacturers constantly seek ways to improve processes, optimize resources, and meet the ever-increasing demands of customers. One potent tool in this quest for perfection is the Focused Improvement (FI) pillar, a cornerstone of World-Class Manufacturing (WCM) methodology. This article delves deep into the FI pillar, exploring its core principles, implementation process, and the remarkable impact it has on manufacturing performance and employee satisfaction.

Understanding the Focused Improvement (FI) Pillar

The FI pillar operates on a simple yet profound philosophy: prioritize losses and eliminate them to bring about overall improvement. By targeting losses, whether they impede equipment efficiency, human work efficiency, or the effective use of production resources, FI strives to unlock significant gains in business performance, meet objectives, and exceed customer requirements. It is a vital component of the comprehensive WCM framework, addressing various structural elements within WCM, including 6S, group activities, visual management, autonomous maintenance, planned maintenance, and more.

Building the FI Pillar

For the FI pillar to stand strong, it requires a supportive foundation:

1. 6S Environment: An integral component of WCM, fosters a clean, organized, and efficient work environment. It exposes and eliminates various abnormalities, such as minor errors, unfulfilled basic conditions, hard-to-access areas, contamination sources, quality defects, unnecessary items, and unsafe areas.

2. Cross-functional Teams: FI thrives on collaboration among a diverse group of individuals who share a common loss. These teams identify improvement opportunities, plan and implement changes, and consolidate gains. Responsibilities are clearly assigned within the group to ensure effective implementation.

3. Visualized Perspective: Visual management aids in communication, root cause analysis, and result monitoring. It provides a tangible perspective on losses, making it easier to comprehend and address the issues at hand.

Categories of Losses Addressed

The FI pillar focuses on three broad categories of losses:

1. Equipment Efficiency Losses: These encompass challenges such as equipment failure, breakdowns, downtime, setup and adjustment issues, cutting tool challenges, minor stoppages, and speed discrepancies.

2. Human Work Efficiency Losses: This category targets issues like management challenges, inefficient operating motions, organizational inefficiencies, logistic problems, and measurement and adjustment difficulties.

3. Resource Utilization Losses: The FI pillar addresses energy losses, die, jig, and tool breakage issues, as well as yield challenges.

The Role of Measurement

Measurement is the lifeblood of the FI pillar. As the saying goes, "That which cannot be measured cannot be improved." The aim of measurement in FI is to assess the performance of WCM structural elements accurately. Key considerations for effective measurement include:

1. Alignment with Strategy: Measurements should support organizational strategy and priorities to gain a competitive edge.

2. Reflecting Customer Demands: Measurements must reflect the demands and expectations of customers, ensuring that their needs are met.

3. Root Cause Identification: Measurements should aid in identifying the root causes of problems rather than merely addressing symptoms.

4. Flexibility and Innovation: The measurement system should be flexible, encouraging innovation and proactive problem-solving.

5. Encouraging Action: Measurements should motivate individuals and teams to take action and drive improvements.

Tools for Control

Control is a fundamental aspect of the FI pillar. It ensures that processes remain stable and deviations are promptly addressed. The tools used to achieve this control include:

1. Plans and Targets: Clearly defined plans and targets guide the improvement process.

2. Tolerance Margins: Establishing acceptable tolerance levels helps in monitoring variations.

3. Actual Measurements: Regular measurements track performance against established standards.

4. Gap Analysis: Identifying disparities between planned and actual performance prompts corrective actions.

5. Corrective Actions: Implementing corrective actions is essential to maintain control over processes.

The FI Implementation Process

The FI pillar follows a systematic ten-step implementation process:

1. Selection of the Subject: Identify the area or process that requires improvement.

2. Determination of Objectives: Clearly define the objectives for improvement.

3. Assembling the Team: Form a cross-functional team with the necessary expertise.

4. Assessment of Current Conditions: Analyze the current state of affairs in the chosen area.

5. Creation of the FI Plan: Develop a comprehensive plan for improvement.

6. Analysis: Dive deep into the data to understand the root causes of losses.

7. Implementing Improvement: Execute the planned improvements.

8. Obtaining Results: Measure and evaluate the results of the implemented changes.

9. Standardization: Establish standardized processes to sustain improvements.

10. Deployment and Vertical Replication: Expand successful improvements to other areas of the organization.

Perspectives on Implementation

FI implementation can be viewed from two perspectives: management and process levels.

Management Level: At this level, management is responsible for setting up cross-functional teams, committing to improvement, defining FI objectives, establishing relevant measures, and taking ownership of actions to ensure accountability.

Process Level: Here, the focus shifts to selling the FI system to all team members, emphasizing benefits and objectives. Understanding processes, drivers, and contextual factors is crucial. The design of the FI system, including performance measures, data collection systems, and reporting frequencies, takes place at this level. Continuous improvement through benchmarking and target setting is also essential.

Choosing the Right Performance Measures

Selecting appropriate performance measures is paramount for the success of the FI pillar. Considerations include:

1. Criticality: Prioritize measures critical to the manufacturer and areas with poor performance.

2. Cost-Benefit Analysis: Weigh the benefits of improving a variable against the cost of data collection and reporting.

3. Practicality: Assess the practical implications and challenges of collecting measurements.

4. Avoiding Overload: Avoid an excessive number of measurements to prevent analysis paralysis, save time, and reduce costs.

5. Active vs. Passive: Categorize measurements as active (directly impacting critical success factors) or passive (indirectly related).

The Focused Improvement (FI) pillar is an indispensable element of World-Class Manufacturing (WCM), offering a systematic approach to identifying and eliminating losses across various operational dimensions. With its emphasis on measurement, control, and continuous improvement, FI equips manufacturing organizations with the tools and strategies needed to achieve excellence in today's competitive landscape. Implementing FI, both at the management and process levels, empowers businesses to optimize performance, reduce waste, and consistently meet customer demands. The FI pillar isn't just a methodology; it's a mindset that propels manufacturers to reach new heights in the ever-evolving world of manufacturing excellence.