Lean Management – Unit 01 – LO2 Be able to implement the productivity needs analysis process

2.1 Describe the process for conducting a productivity needs analysis

a. Describe the need for a structured balanced approach to business understanding and the 3 key methods of displaying data in a Productivity Needs Analysis.

b. Why is it important for a company to conduct a Productivity Needs Analysis before starting an improvement activity?

c. How does a Productivity Needs Analysis help you & your company plan?

d. Describe and explain the structured approach to measurement.

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e. Quality measure that you are familiar with and how it is used.

2.2 Undertake a productivity needs analysis in a selected organisation

Productivity Needs Analysis

Description Run 1 Run 2 Run 3 Run 4
GOOD PLUGS 0 8 13 20
BAD PLUGS 0 2 2 0
Highest Batch Size 5 1 1 1
Work in Progress(Anything that station 1 has touched at the end of the round) 33 15 0 3
Lead Time to Customer >9mins >9mins 7 mins 58 secs 8 mins 48
Sales (L1 x £1 per Plug) £0 £8 £13 £20
Raw Materials = (L1 + L2 + L4 x 50p) £16.50 £12.50 £7.50 £11.50
Labour (10p per operator) £4.50 £4.50 £4.00 £4.50
PROFIT/LOSS =L6 – (L7 + L8) £21 Loss £9 Loss £1.50 PROFIT £4.00
PROFIT
Station 1
(Cycle times) Work (Secs) 4.5 sec 2 secs 11 secs 11 secs
Walk (steps) 8 secs 1 sec 1 sec 1 sec
Station 2
(Cycle times) Work (Secs) 18 sec 13 sec 20 secs 15 secs
Walk (steps) 8 secs 1 sec 1 sec 1 sec
Station 3
(Cycle times) Work (Secs) 54 secs 47 secs 10 sec 24 secs
Walk (steps) 8 secs 1 sec 1 sec 1 sec
Station 4
(Cycle times) Work (Secs) 18 secs 23 secs 19 secs 12 secs
Walk (steps) 8 secs 1 sec 1 sec 1 secs
Totals Work (Secs) 94.5 secs 85 secs 60 secs 62 secs
Walk (steps) 32 secs 4 secs 4 secs 4 secs
Tech Cert Flow Process 11.9.