bb wk1 190 lean performance metrics

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Black Belt Training Ford Proprietary

Copyright © 2005-2006, Ford Motor Company – All Rights Reserved

Lean Performance

Metrics



Lean Performance Metrics

Black Belt Training Slide 2

Module Objectives

By the end of this module, the participant will be able to :

Understand the importance of Lean Performance Metrics in identifying

waste and measuring successful progress on our Lean journey.

Define, calculate, and explain why Lean Performance Metrics are

used:• The two types of measurables

• First Time Through

• Dock-to-Dock

• Build-to-Schedule• Overall Equipment Effectiveness

• Total Cost

• SHARP and

• Attitude Surveys





The FPSMeasurables were

designed to help

plants, individualoperations, and

work groups assess

their performance

FPS Measurables





Two Types of Measurables

Manufacturing Measurables

First Time Through (FTT)

Dock-to-Dock (DTD)

Build-to-Schedule (BTS)

Overall Equipment Effectiveness (OEE)

Total Cost (TC)

Work Group Issues

SHARP

Attitude Surveys





FTT is the percentage of units processed at theEvaluation Point that meet Quality Guidelines

the first time without being repaired, retested,

returned from within the plant, or scrapped.

First Time Through (FTT)

Total Units Processed - Units Not OK

Total Units ProcessedFTT @ an EP = X 100 %





Dock-to-Dock Time is theelapsed time between theunloading of rawmaterials and the releaseof the finished goods for shipment

Dock-to-Dock (DTD)

PRODUCTION DTD = Inventory (Control Part)

End of Line Rate





BTS is the percentage of products scheduled for a given day

that are produced on that day in the right sequence

Build-to-Schedule (BTS)

BTS % = % Volume x % Mix x %Sequence





OEE is a measure of the abilityof a piece of equipment or aprocess to consistently produceproducts which meet Quality

Guidelines without disruption atthe designated cycle rate

Overall Equipment Effectiveness (OEE)

OEE = Availability X Performance Efficiency X Quality Rate





Total Cost (TC)

Total Cost measures total cost per unit





SHARP is a detailed, quantitative evaluation that emphasizesproactive improvements in health and safety processes

Safety and Health Assessment Review Process





Attitude Surveysmeasure employeeattitudes about their jobs and conditions in

the work environment

Attitude Surveys





How are Measurables used?

Plants use measurables to: Analyze trends

Solve problems

Verify results





Objectives Review

The participant should be able to:

Explain the importance of Lean Performance Metrics in identifyingwaste and measuring successful progress on our Lean journey.

Define, calculate, and explain why Lean Performance Metrics areused:

• The two types of measurables

• First Time Through

• Dock-to-Dock

• Build-to-Schedule

• Overall Equipment Effectiveness• Total Cost

• SHARP and

• Attitude Surveys

bb wk1 190 lean performance metrics

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