brown paper mcrs
TRANSCRIPT
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Systems
SystemsMethodology
BROWN PAPER – THE GUN & THE SIMPLE TOOL FOR SYSTEMS IMPROVEMENT IN ALL ORGANIZATION FUNCTION
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Systems
brown paperbrown papercurrent systemcurrent system
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Systems
a brown paper is a a brown paper is a presentation presentation aid aid which is used to outline which is used to outline
current systems current systems and to identify and to identify systems systems weaknessesweaknesses. it is also . it is also
used to outline used to outline proposedproposed or or upgrade upgrade systemssystems..
brown paper - definition
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Systems
mini flow - definition
a mini-flow is a a mini-flow is a presentation aidpresentation aid. it is . it is used to outline a current or used to outline a current or proposed proposed
systemsystem. it is normally an . it is normally an a4 flow a4 flow diagram diagram which can be used as an which can be used as an
handout, an ohp slide or filed in an handout, an ohp slide or filed in an area book. it is often used as an exact area book. it is often used as an exact
copy of a brown paper.copy of a brown paper.
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Systems
completing a brown paper - 10 steps
1 pre present
2 copies
3 understand
4 preliminary
5 test
6 finalise
7 critique
8 test
9 present
10 action
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Systems
separate two copies into two piles and file second copy
go through documents with client, understand detail
write details on copy with client separate documents into five piles:
forecast order entry planning control reporting
place brown paper in ‘rough’ order with one dab of glue
understand flow and review with client to confirm ‘complete’ brown paper
brown paper - detail
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Systems
missing system elements blank copies only only one copy mismatched mini-flow & brown
paper too much detail too little detail ‘so what ?’ syndrome brown paper deterioration size of brown paper client disagreement out of date
brown paper - typical pitfalls
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Systems
observations
recap
volumes
data developme
nt
master schedule
dry run
implementation plan
installation
see implementation
steps
observations
lost time summary
action plans
new planning rates
critique
system objectives
proposed system
identified training needs
training flows
resource levels
implementation plan
volume forecast
training sessions
sequence of operations
resourcesactivities
machines/ processes system
straining
activity listing
statisticsbrown paper
current system
diagnostics
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Systems
critiquescritiques
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Systems
critiques - system facetsis information complete?is information timely?is information correct?is information of use / relevant?is the level of detail too little / too much?are there system disconnects?is there too much paperwork?what can be computerised for ease of
use?is the system wrong or are people just
not using the information?
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Systems
forecast - possible critiques of the system
out of date datano basic sales info
to productionwrong people
involvedinflexible for
production capacity
not used
does not exist
not enough detail
produced too late
wrong timescale
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Systems
plan - possible critiques of the systemwrong standardsfrequent changesdoesn’t relate to
forecastcustomer resources
availablenot usedincompatible plansno contingency plansno comparison to actual
inflexibletimelinessnot enough detailno procedureno commitment
meetingsillogical runsdistributed to wrong
people
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Systems
control of execution - possible critiques of the system
wrong standards
frequency
no short interval control
wrong / irrelevant information
information missingwrong area duplicationconsistencypeople cannot fill
reports in
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Systems
reports - possible critiques of the system
no review meeting
don’t generate actions
no report
not used
consistency
do not review standards
doesn’t feed into production control
no agenda / poor meeting inappropriate information timelinessattention to detail report not user friendly frequency
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Systems
observations
recap
volumes
data developme
nt
master schedule
dry run
implementation plan
installation
see implementation
steps
observations
lost time summary
action plans
new planning rates
critique
system objectives
proposed system
identified training needs
training flows
resource levels
implementation plan
volume forecast
training sessions
sequence of operations
resourcesactivities
machines/ processes system
straining
activity listing
statisticsbrown paper
current system
diagnostics
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Systems
system - system objectives
measure, control and manage the area / business so that performance can be improved, and the improvement process sustained. links company strategy, operational strategy and day to day execution
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Systems
proposed system brown paperdescribes a complete proposed system
no system disconnects
links logically with its interfaces
answers all critique points raised on existing brown paper
reviewed with the project leader
reviewed and signed off by the client
neat and professional manner
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Systems
Short Short TermTerm
ForecastForecast
MasterMasterScheduleSchedule-activity-activity-people-people
-materials-materials
Daily/WeeklyDaily/WeeklyProductionProduction
PlanPlan
ShortShortIntervalIntervalControlControl
Daily/WeeklyDaily/WeeklyOperatingOperating
ReportReport
DowntimeDowntimeReportReport
Daily/WeeklyDaily/WeeklyActionActionPlansPlans
WeeklyWeeklyProductionProduction
ReportReport
Weekly Management Weekly Management ReportReport
- Production- Production-Sales-Sales
-Quality-Quality-Safety-Safety
-Engineering-Engineering
MonthlyMonthlyBusinessBusinessReportReport- P & L- P & L
- Budget- Budget
MonthMonthly ly forecaforecast st reviewreview
MonthlyMonthlyPlanningPlanningMeetingMeeting
Weekly Weekly planning planning
CommitmeCommitment Meetingnt Meeting Daily Daily
ProductioProduction n
PerformanPerformance Reviewce Review
WeeklyWeeklyActionActionPlansPlans
Weekly Weekly Production Production
Performance Performance ReviewReview
WeeklyWeeklyActionActionPlansPlans
Weekly Weekly ManagemenManagemen
t t PerformancPerformanc
e Reviewe Review
Monthly Monthly BusinessBusinessReview Review MeetingMeeting
generic management control system
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Systems
RE-DESIGNIG ORGANIZATION STRUCTURE
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SystemsBrown paper is simple & quick methodology with many benefit Business process mapping & re-engineering Designing organization structure Restructuring system & organization (make more simple &
flexible) KPI design Job analysis Performance system design Find missing link the integration system (SAP, BSC, Lean, ISO,
MBNQA, etc) Flow chart design SOP design Form & format design Working instruction design Improvement system Designing control & check system Designing report system Designing planning system Integration all system in organization etc