gap analysis & action plan launch created with funding from wired nw

Created with Funding from WIRED NW

By the end of today’s class, you should be able to:

Use Gap Analysis methodology, Current State vs. Future State Gap Analysis

Apply Gap Analysis to your organizationApply Problem Solving techniquesConfirm stretch goals and perform gap analysis from

current state of each stretch goal

Launch an Action Plan

Gap Analysis &Action Plan Launch

Created by funding from WIRED NW

3/14/2002

ICoils5 days

I4600 L2400 R

I1100 L600 R OCT = 62 sec

D/R = 62 secC/O = 0REJ = 6%U/T =100%2 Shifts

27, 600 sec. Avail.

OCT = 40 secD/R = 40 secC/O = 0REJ = 7%U/T = 100%2 Shifts

27,600 sec. Avail.

Shipping

Staging

III1600 L850 R

1200 L640 R

2700 L1440 R

FerrousMetals Co.

500 ft coils

Tues & Thurs

Machine

1

OCT= 39 secD/R = 39 secC/O = 10 minREJ = 4%U/T= 100%2 Shifts

27, 600 sec Avail.

OCT= 1 secondD/R = 1 secondC/O = 1 hourREJ = 3%U/T = 85%27,600 sec. avail.EPE = 2 weeks

Stamp

200 t

Weld

1

OCT = 46 secD/R = 46 secC/O = 10 minREJ = 5%U/T = 80%2 Shifts

27,600 sec. Avail.

1x daily

Sub-Assembly

1

Assembly

1

MRP

18,400 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs

2 Shifts

Highland ManufacturingSheet Metal HousingsCurrent State(Date)

Daily ShipSchedule

Weekly Schedule TT = 60 sec.

ManchesterAvenue

6-weekForecast

Weeklyfax

ProductionControlMRP

90/60/30 dayForecasts

DailyOrder

5 days 7.6 days 1.8 days 2.7 days 2 days 4.5 days

1 sec. 39 sec. 46 sec. 62 sec. 40 sec.

Lead Time=23.6 days

Process Time= 188 sec

Let’s apply gap analysis to your organization

We have collected the data along our past class sessions:

•Refer back to your Policy Deployment plans•Review your X matrix•Review your current state VSM(s)•Identify opportunities to apply Standard Work


Three key questions:

•What are the gaps?•What are the most important?•Where are the Kaizen opportunities?

3/14/2002

ICoils5 days

I4600 L2400 R

I1100 L600 R OCT = 62 sec


27, 600 sec. Avail.


27,600 sec. Avail.

Shipping

Staging

III1600 L850 R

1200 L640 R

2700 L1440 R

FerrousMetals Co.

500 ft coils

Tues & Thurs

Machine

1


27, 600 sec Avail.


Stamp

200 t

Weld

1


27,600 sec. Avail.

1x daily

Sub-Assembly

1

Assembly

1

MRP

18,400 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs

2 Shifts


Daily ShipSchedule


ManchesterAvenue

6-weekForecast

Weeklyfax



DailyOrder



Lead Time=23.6 days



What are the gaps?

•Review your policy deployment plans•Review your X Matrix•Compare your goals to your current situation•Compare your Current State VSM to your goals•What in your policy deployment flows towards an opportunity for you?

3/14/2002

ICoils5 days

I4600 L2400 R

I1100 L600 R OCT = 62 sec


27, 600 sec. Avail.


27,600 sec. Avail.

Shipping

Staging

III1600 L850 R

1200 L640 R

2700 L1440 R

FerrousMetals Co.

500 ft coils

Tues & Thurs

Machine

1


27, 600 sec Avail.


Stamp

200 t

Weld

1


27,600 sec. Avail.

1x daily

Sub-Assembly

1

Assembly

1

MRP

18,400 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs

2 Shifts


Daily ShipSchedule


ManchesterAvenue

6-weekForecast

Weeklyfax



DailyOrder



Lead Time=23.6 days



What are the most important?

Consider :Strategic priorities

SafetyQualityCostDeliveryService

3/14/2002

ICoils5 days

I4600 L2400 R

I1100 L600 R OCT = 62 sec


27, 600 sec. Avail.


27,600 sec. Avail.

Shipping

Staging

III1600 L850 R

1200 L640 R

2700 L1440 R

FerrousMetals Co.

500 ft coils

Tues & Thurs

Machine

1


27, 600 sec Avail.


Stamp

200 t

Weld

1


27,600 sec. Avail.

1x daily

Sub-Assembly

1

Assembly

1

MRP

18,400 pcs/mo-12,000 “L”-6,400 “R”Tray = 20 pcs

2 Shifts


Daily ShipSchedule


ManchesterAvenue

6-weekForecast

Weeklyfax



DailyOrder



Lead Time=23.6 days



Where are the Kaizen opportunities?

• • • • •

And there’s more!


Confirm stretch goals

• • • •

perform gap analysis from the current state of each stretch goal


Narrow the Kaizen opportunities to one that you think can be deployed within the next month at your organization.


Begin your Kaizen Charter

•Who will be your team?•How will you approach it?•What do you plan to accomplish at your company event within the next month?


•Gather tools and supplies•Build or borrow Kaizen toolkits

•Communicate, communicate, communicate!

•Anticipate participants’ needs •Large area to gather, and later report out•Clearly articulate the current situation•Provide agenda, schedule•Provide food and beverages


•Let the opportunity begin!

•Allow time for participants to bring back findings and prepare presentation

•Invite appropriate people to the presentation

•Top managers•People who can influence, or who will be influenced by the findings•Learners who might participate in future Kaizen events


•Thank everyone for their participation and interest

Thank you!


•Now it’s your turn


This assignment should take about 12 hours (your two hours independent assignment for this week, plus this will count in lieu of another classroom session: eight hours class time and the two hours independent assignment time for that session). 1.Meet with your mentor and review the gap analysis discussed in today’s session.2.Mutually agree on opportunities to apply what was learned today, using as many tools as possible.3.Execute a Kaizen at your organization, and prepare a 15 minute presentation to report out at next session.


gap analysis & action plan launch created with funding from wired nw

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