standard slides for mrm presentation
TRANSCRIPT
COMPANY NAME
COMPANY LOGO
OEM LOGO
CLUSTER :
Hosted By :
MRM No :
Venue :
Date :
COMPANY NAME
COMPANY NAME
COMPANY LOGO
OEM LOGO
Front View of company
Photo Photo
Last month view
Current month view
Date : Date :
COMPANY NAME
COMPANY LOGO
OEM LOGO
Scrap Yard View
Frequency of Disposal :
Last date of Disposal :
Next due date :
Maintained by :
2S Action Initiated :
Area Utilised Initial :
Area Utilised Current :
Photo Photo
Last month view
Current month viewDate : Date :
COMPANY NAME
COMPANY LOGO
OEM LOGORed Tag Campaign
Zone 1 2 3 4 5 6 7 8 9 10 Total
Red Tag Put
Red Tag Removed Date of Oldest Pending Tag -
Cummulative Area Recovered - Sq. Mtr.
460
340300
100
430
310
240
90
0
50
100
150
200
250
300
350
400
450
500
Dec. 07 Jan. 2008 Feb. 2008 Mar. 2008
Months
Nos
Red Tag Campaign
Photo
Red Tag Area Photo
Date :
Date :
COMPANY NAME
COMPANY LOGO
OEM LOGOWorst Point Photography
Photo Photo
Zone 1 2 3 4 5 6 7 8 9 10 CumTotal
WPP Identified
WPP Eliminated
Before After
Date : Date :
COMPANY NAME
COMPANY LOGO
OEM LOGO
Zonal Board Photo of one Zone Every month
Worst Point Photography
Photo Photo
Before After
Date : Date :
Date :
COMPANY NAME
COMPANY LOGO
OEM LOGOFix Point Photography
Zone 1 2 3 4 5 6 7 8 9 10 Cum.Total
FPP IDENTIFIED
FPP STAGE
FPP STAGE- I = Initial Photo, FPP STAGE- II = Red Tagged, FPP STAGE-III = Red Tag RemovedFPP STAGE- IV = 2S Shining, FPP STAGE- V = 3S Shining , FPP STAGE- VI = Sustenance
FPP INITIAL PHOTOOF ANY ZONE
Date :
PHOTO OF
FPP POINT MARKED
ON GROUND
Date :
COMPANY NAME
COMPANY LOGO
OEM LOGOFixed Point Photography
Initial Photo Red Tagged Photo Red Tag Removed Photo
2S Shining Photo3S Shining PhotoSustenance Photo
Date :
ZONE NO :
Date : Date :
Date : Date : Date :
STAGE- I STAGE- II STAGE- III
STAGE- VI STAGE- V STAGE- IV
COMPANY NAME
COMPANY LOGO
OEM LOGO2S SHINING
ZONE NO :
Photo Photo
Zone 1 2 3 4 5 6 7 8 9 10 CumTotal
WPP Identified
WPP Eliminated
Before After
Date : Date :
COMPANY NAME
COMPANY LOGO
OEM LOGO5S SCORE
40
35
50
0
25
50
75
100
1S
2S
3S4S
5S 50
45
60
0
25
50
75
100
1S
2S
3S4S
5S
Last Month Current Month
Zone 1 2 3 4 5 6
1 S 35 30 18 27 70 40
2 S 37 17 22 60 35 26
3S 45 50 50 51 54 63
1S MINIMUM – ZONE 5 2S MINIMUM – ZONE 23S MINIMUM – ZONE 4
1S MINIMUM – ZONE 5 2S MINIMUM – ZONE 23S MINIMUM – ZONE 1
Red < 49Yellow 50 to 59Green > 60
COMPANY NAME
COMPANY LOGO
OEM LOGO
3 S Table
COMPANY NAME
COMPANY LOGO
OEM LOGOSafety
25
42
73
121
22
38
62
114
0
20
40
60
80
100
120
140
Dec. 07 Jan. 2008 Feb. 2008 Mar. 2008
Months
Nos
Green Tag Campaign
Zone 1 2 3 4 5 6 7 8 9 10 Cum.Total
Green Tag Put
Green Tag Removed Date of Oldest Pending Tag -
Green Tag Campaign
Photo
Date :
COMPANY NAME
COMPANY LOGO
OEM LOGO
Photo Photo
Before After
Date : Date :
Photo Photo
Date : Date :
UnsafeAct
UnsafeCondition
SafetyUnsafe Act / Condition
COMPANY NAME
COMPANY LOGO
OEM LOGO3M Status
Zone
MUDA 1 MUDA 2 MUDA 3 MUDA 4 MUDA 5 MUDA 6 MUDA 7 MURA MURI TOTAL
I E D I E D I E D I E D I E D I E D I E D I E D I E D I E D
1 6 4 3 4 2 2 4 3 2 3 2 1 3 2 1 3 1 1 - - - - - - 2 2 1 25
15 11
2 7 3 2 5 2 1 2 1 1 2 2 1 2 1 1 2 2 1 - - - 2 2 1 1 1 1 23
16 8
3 6 4 5 5 3 3 3 2 1 3 2 1 3 2 1 2 1 1 1 1 1 3 1 1 5 3 2 31
20 15
4 11
7 7 9 6 5 8 5 4 8 6 6 5 3 1 5 4 2 5 2 2 3 2 1 6 5 5 60
41 36
Total
24
18
17
23
13
11
19
11
8 16
12
10
13
8 4 12
8 5 6 3 3 8 5 3 14
11
9 139
92 70
(1) MUDA of Overproduction ( 2) MUDA of Stock (3) MUDA of Conveyance (Transport)
(4) MUDA of Waiting (5) MUDA of Operation Itself (6) MUDA of Movement of Worker
(7) MUDA of Production of Inferior good. ** MURA :- System Unbalance ** MURI :- Over Stress / Strain
I = Identified E = Eliminated D = Documented
COMPANY NAME
COMPANY LOGO
OEM LOGO
EXAMPLE OF MUDA / MURA / MURI
ZONE :
KAIZEN THEME :
PROBLEM STATUS :
PROBLEM ANALYSIS :
ROOT CAUSE :
KAIZEN SHEET
KAIZEN IDEA:
COUNTER MEASURE :
BEFORE AFTER
RESULTS :
TEAM:
IDEA BY:
STARTING DATE :
COMPLETION.DATE :
BENCH MARK:
TARGET:
BENEFITS
QUALITATIVE QUANTITATIVE
M
Q
C
D
P
S
Benefits :
PLAN FOR HORIIZONTAL DEPLOYMENT
S WHERE WHO WHEN STATUS
1
St. Size Photo
COMPANY NAME
COMPANY LOGO
OEM LOGO
UOM = Nos
9
8 8
7
6
5 5 5
4
0
1
2
3
4
5
6
7
8
9
10
Ap
r-0
7
Ma
y-0
7
Jun
-07
Jul-0
7
Ao
ug
-07
Se
p-0
7
Oct
-07
No
v-0
7
De
c-0
7
Months
UOM = No.
34
2
0
1
2
3
4
5
6
7
8
9
10
2004-05 2005-06 2006-07
Year
Nos
Customer Complaints
BETTER
TARGET “0”
RESPONSIBILITY : NAME & DESIGNATION
Nos
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
UOM = PPM
27000
2000015000
900011000
30000
30000
3100035000
0
25000
50000
75000
100000
Months
PPM
UOM = PPM
50000
35000
75000
0
25000
50000
75000
100000
2004-05 2005-2006
2006-07
Year
PPM
Customer Returns
BETTER
(Total no. of returns)Customer Returns = ------------------------------- x 106
(Total no. of units sold)
TARGET 100 PPM
RESPONSIBILITY : NAME & DESIGNATIONPAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
UOM = PPM
12000
44000
24000
1400011000
21000
14000
24000
12000
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
Ap
r-0
7
Ma
y-0
7
Jun
-07
Jul-
07
Au
g-0
7
Se
p-0
7
Oct
-07
No
v-0
7
De
c-0
7
Months
UOM = PPM
17000
34000
26000
22000
0
5000
10000
15000
20000
25000
30000
35000
40000
45000
50000
2003-04 2004-05 2005-06 2006-07
Year
PPM
In Process Rejection
BETTER
(Total no. of defectives produced )In Process Rejection = --------------------------------------------------- x 106
(Total no. of units produced in the process)
RESPONSIBILITY : NAME & DESIGNATION
TARGET-100ppm
PPMPAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
AFTER
EXAMPLE OF POKA YOKE
ZONE : NAME : POKA YOKE SHEET DATE :
PROBLEM PREVENTION
ALARM
ORIGIN
PROCESS DETECTION CONTROL
SOLUTION
KEY IMPROVEMENT SHUTDOWN
BEFORE
Sketch / Photo Sketch / Photo
COMPANY NAME
COMPANY LOGO
OEM LOGO
UOM = Numbers
36 7
1114
9
13
21
27
0
5
10
15
20
25
30
35
Months
UOM = Numbers
2 2
5
9
0
5
10
15
20
25
30
35
2003-04 2004-05 2005-06 2006-07Year
Nos
Inventory Turn Ratio
BETTER
(Material cost of sales in particular month) ITR = ---------------------------------------------------------- X 12 (Inventory RM+WIP+FG as on date)
RESPONSIBILITY : NAME & DESIGNATION
TARGT-35
NosPAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
UOM = Rs/ Employee
7 7.5 89 9 9.5
1112
16
0
5
10
15
20
25
Months
UOM = Rs / Employee
34.75
6 6
0
5
10
15
20
25
2003-04 2004-05 2005-06 2006-07
Year
Value Added Per Employee
BETTER
TARGET:-
Sales - Variable Cost (Annualized) Value Added Per Employee = --------------------------------------------
Total No. of Employees
RESPONSIBILITY : NAME & DESIGNATION
Rs in thousandRs in thousand
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
UOM = NOS
1
1.8
2.32.7
3.43.7
4.64.9
5.1
0
1
2
3
4
5
6
Apr-07
May
-07
Jun-
07
Jul-0
7
Aug-07
Sep-07
Oct-0
7
Nov-0
7
Dec-0
7
Months
UOM = NOS
2 2
3
2.5
0
1
2
3
4
5
6
2003-04 2004-05 2005-06 2006-07Year
Value Added Per Employee Cost
BETTER
Sales - Variable Cost (Annualized) Value Added Per Employee Cost = ------------------------------------------------
Total Employee Cost
RESPONSIBILITY : NAME & DESIGNATION
Nos Nos
TARGET-6
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
UOM = Hours
4750 49004600
2000
26003000
37504100
4250
0
1000
2000
3000
4000
5000
6000
7000
Apr-07
May-07
Jun-07
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Months
Un
its
UOM = Hours
2000 2100
31002700
0
1000
2000
3000
4000
5000
6000
7000
2003-04 2004-05 2005-06 2006-07Year
Labour Productivity
BETTER
TARGET:-
Labor No of unit produced as per customer requirement Productivity = --------------------------------------------------------------------------- x 100
Total Number Of Employees Hours ( Direct, Indirect,Administrative)
RESPONSIBILITY : NAME & DESIGNATIONHrs Hrs
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
UOM = Rs. / M^2
11.5
1
22.5
1.5
33.5
5
0
2
4
6
8
Ap
r-0
7
Ma
y-0
7
Jun
-07
Jul-0
7
Au
g-0
7
Se
p-0
7
Oct
-07
No
v-0
7
De
c-0
7
Months
UOM = Rs. / M^2
2 2
2.83.2
0
2
4
6
8
2003-4 2004-05 2005-06 2006-07
Year
Floor Space Utilization
BETTER
(Total Sales in particular month) Floor Space Utilization = ------------------------------------------ (Shop floor space in Sq.Mtrs.)
RESPONSIBILITY : NAME & DESIGNATION
In thousand In thousand
PAST TREND
TARGET:-
COMPANY NAME
COMPANY LOGO
OEM LOGO
UOM = %
45 46 48 50 51
65
7580
58
0
20
40
60
80
100
Apr-07
May-07
Jun-07
Jul-07 Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Months
UOM = %
3033
3741
0
20
40
60
80
100
2003-04 2004-05 2005-06 2006-07Year
Delivery Schedule Achievement
BETTER
(Total no. of despatches achieved) Delivery Schedule Achievement = --------------------------------------------------------------------------------------- x100 (Total no. of despatches planned -as required by the Customer)
RESPONSIBILITY : NAME & DESIGNATION
TARGET-100%
%%
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
Inventory Control
RED GREY GREEN
RM % % %WIP FG
INDIRECT MATERIAL
Initial DefinitionGreen <30 days. Grey 31 to 45 days.Red above 45 days.
RESPONSIBILITY : NAME & DESIGNATION
COMPANY NAME
COMPANY LOGO
OEM LOGOInventory
Total Inventory
60 55 5065 70
30 35 3630 27
10 10 14 5 3
0%
20%
40%
60%
80%
100%
Aug-05 Sep-05 Oct-05 Nov-05 Dec-05
Month
%
Red
Gray
Green
RESPONSIBILITY : NAME & DESIGNATION
COMPANY NAME
COMPANY LOGO
OEM LOGO
Raw Material
60 55 5065 70
30 3536
30 27
10 10 145 3
0%
20%
40%
60%
80%
100%
Aug-05 Sep-05 Oct-05 Nov-05 Dec-05
Month
%
WIP
60 55 5065 70
30 35 36
30 2710 10 14 5 3
0%
20%
40%
60%
80%
100%
Aug-05 Sep-05 Oct-05 Nov-05 Dec-05
Month
%
Finished Goods
60 55 5065 70
30 3536
30 27
10 10 145 3
0%
20%
40%
60%
80%
100%
Aug-05 Sep-05 Oct-05 Nov-05 Dec-05
Month
%
Inventory
RESPONSIBILITY : NAME & DESIGNATION
Indirect Material
60 55 5065 70
30 35 3630 27
10 10 145 3
0%
20%
40%
60%
80%
100%
Aug-05 Sep-05 Oct-05 Nov-05 Dec-05
Month
%
COMPANY NAME
COMPANY LOGO
OEM LOGO
Machine Break Down
UOM=Hours
45
52
43 41 40 3935
25
50
0
10
20
30
40
50
60
70
80
90
100
Apr-07 May-07
Jun-07 Jul-07 Aug-07
Sep-07
Oct-07 Nov-07
Dec-07
Months
UOM = Hours
8075 76
68
0
10
20
30
40
50
60
70
80
90
100
2003-04 2004-05 2005-06 2006-07
Year
BETTER
RESPONSIBILITY : NAME & DESIGNATION
TARGET-”ZERO”
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGOMachine Break Down Frequency
UOM = NOS
16
1312
1110 10
9 9
16
0
2
4
6
8
10
12
14
16
18
20
Apr-07 May-07
Jun-07 Jul-07 Aug-07
Sep-07
Oct-07 Nov-07
Dec-07
Months
UOM = NOS
40
3633
31
0
10
20
30
40
50
2003-04 2004-05 2005-06 2006-07
Year
BETTER
RESPONSIBILITY : NAME & DESIGNATION
TARGET-ZERO
NosNos
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
Absenteeism
UOM = %
8
7 7 76.5
66.5
6 6
0
3
6
9
12
15
Apr-07
May-07
Jun-07
Jul-07 Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Months
UOM = %
11
98 8
0
3
6
9
12
15
2003-04 2004-05 2005-06 2006-07Year
BETTER
RESPONSIBILITY : NAME & DESIGNATION
%%
TARGET-5%
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
Accident Frequency Rate
UOM :- PPM
55
47
3935
3127
2421
11
0
25
50
75
100
Apr-07
May-07
Jun-07
Jul-07 Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Months
UOM :- PPM
82
67
58
42
0
25
50
75
100
2003-04 2004-05 2005-06 2006-07Y ear
(No. of accidents) Accident Frequency Rate = ------------------------ --------------------------- X 106
(Total man-hours includes overtime)
BETTER
RESPONSIBILITY : NAME & DESIGNATION
TARGET-”ZERO”
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
Accident Severity Rate
UOM = PPM1500
13001140
900825
550412
323 275
0
250
500
750
1000
1250
1500
1750
Apr-07
May-07
Jun-07
Jul-07
Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Months
UOM = PPM
250
500
750
500
0
250
500
750
1000
1250
1500
1750
2001-02 2002-03 2003-04 2004-05Year
BETTER
(Man-hrs lost)Severity Rate = -------------------------------------------- X 106
(Total man-hours ; includes overtime)
RESPONSIBILITY : NAME & DESIGNATIONPAST TRENDPPM PPM
COMPANY NAME
COMPANY LOGO
OEM LOGO
Energy Cost Saving
UOM :- Thousand
5 5.56.3
88.8
11.7
14.1
16.6
18
0
2
4
6
8
10
12
14
16
18
20
Apr-07
May-07
Jun-07
Jul-07 Aug-07
Sep-07
Oct-07
Nov-07
Dec-07
Months
UOM :- Thousand
3.1 3.6 4.1 4.4
0
2
4
6
8
10
12
14
16
18
20
2003-04 2004-05 2005-06 2006-07
Year
Cumulitive In Thousand
BETTER
RESPONSIBILITY : NAME & DESIGNATION
Cum. In Thousands Cum. In Thousands
PAST TREND
COMPANY NAME
COMPANY LOGO
OEM LOGO
Involvement of Staff & Operators in Improvement activities
35
4852
6472 75
79 82 85
0
20
40
60
80
100
Apr'0
7
May
'07
June
'07
July'
07
Aug'07
Sept'0
7
Oct'
07
Nov'07
Dec'07
Jan'0
8
Feb'08
Mar
'08
TARGET-100%
9 1120
0
20
40
60
80
100
2004-05 2005-06 2006-07
Year
% UOM-PERCENTAGE
PAST TREND
UOM-PERCENTAGE%
Better
RESPONSIBILITY : NAME & DESIGNATION
COMPANY NAME
COMPANY LOGO
OEM LOGO
Number of Suggestions per Employee
0.1 0.15
0.3 0.3
0.50.6
0.7
0
0.25
0.5
0.75
1
1.25
1.5
April'07 7-May 7-Jun 7-Jul 7-Aug 7-Sep 7-Oct0
0.25
0.5
0.75
1
1.25
1.5
2004-05 2005-06 2006-07
Year
Nos
PAST TREND
UOM – No /Employee / MonthNos
Better
TARGET-One/ Employee / Month
Data Not Available
RESPONSIBILITY : NAME & DESIGNATION
(Total No. of Kaizens) No. of Suggestions / Employee = -------------------------------------
Total No. of Employees
COMPANY NAME
COMPANY LOGO
OEM LOGO
SR Tool Change No of Tool NO Station / Machine changed/mth < 10 Min 10 to 30 Min > 30 Min
123456789
10Total
Time in Min Total time in min/ mth
SMED Table
RESPONSIBILITY : NAME & DESIGNATION
(Total Setup time in Min / Month) % Setup Time = ------------------------------------- ------------- x 100
Total Available min. /month
COMPANY NAME
COMPANY LOGO
OEM LOGO
Home work
RESPONSIBILITY : NAME & DESIGNATION
Sr.No Home Work Resp Status Target Date
COMPANY NAME
COMPANY LOGO
OEM LOGO
CEO’S PRESENTATION
COMPANY NAME
COMPANY LOGO
OEM LOGOGAP ANALYSIS
RESPONSIBILITY : NAME & DESIGNATION
Sr.No
GAP STATUS ACTION PLAN TARGET
COMPANY NAME
COMPANY LOGO
OEM LOGO
TRAINING STATUS
Zone
Zone Memeber 1S WPP 1S Audit
FPP 2S 2S Audit
3M
COMPANY NAME
COMPANY LOGO
OEM LOGO
Benefits Achieved – Tangible
15
30
50
100
0
20
40
60
80
100
120
Sep-07 Oct-07 Nov-07 Dec-07
Month
Sl.no
Description Benefits
Last Months
Cumulative
1 Red Tagging
2 Kaizens
3Energy Savings
Total Rs.
4
Space RecoveredSq.mtr
Rs. In Thousands
UQM= Rs
COMPANY NAME
COMPANY LOGO
OEM LOGO
Intangible – Sales Trend Graph
RESPONSIBILITY : NAME & DESIGNATION
COMPANY LOGO
Sr.No Intangible Benefits Sales
23
5
810
89.5
11
15
0
5
10
15
20
Month
Rs in Lac
UOM=Rs
COMPANY NAME
COMPANY LOGO
OEM LOGOFOCUSSED AREA
S.No. DESCRIPTION ACTION PLAN
1 CUSTOMER COMPLAINTS
2 CUSTOMER RETURNS
3 INPROCESS REJECTION
4 DELIVERY SCHEDULE ADHERENCE
5 ITR
6 VAPCO
7 FLOOR SPACE UTILISATION
COMPANY NAME
COMPANY LOGO
OEM LOGO
Special Achievements & Other IssuesIf Any
COMPANY NAME
COMPANY LOGO
OEM LOGO
Sr Key Indicator Target Apr 07
May 07
June 07
July 07
Aug 07
Sept 07
Oct. 07
Nov. 07
Dec. 07
Jan. 08
Feb 08
March 08
1 Cust. Complaint
2 Cust. Return
3 In Process Rej
4 Labor Productivity
5 ITR
6 Delivery Schedule Adherence
7 Vapco
8 Floor Space Utilization
9 Accident Frequency
10 Absenteeism
11 Machine Breakdown Hrs.
12 Employee Suggestions
Summary of Key Indicators for the year 2007-08
COMPANY NAME
COMPANY LOGO
OEM LOGO
THANK YOU