team based migration

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From Supervisory Controlto Team Based Migration

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Introduction

• Process to migrate the management of the production process from “Shop floor supervisory control system” to a “Self managed team based management system”

• The involvement of the supervisory function to be more indirect and facilitative in nature.

• Involves groups of people working with individual objectives and targets, keeping in sight overall organizational goals.

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Management System Migration

Supervisor

Team Leader

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Direct involvement

In-direct involvement

Semi-directive

Tight control

Train and Develop

Facilitate and supportive

Shop floor Supervisory

control system

Shop floor team based

control system

Self managed team based

management system

Migration path

Concept

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• Tighter control conducted by supervisors• Hourly control at the shop floor. • Focus is to reduce obvious loss time/ inefficiency. • System provides insight to the inefficiency at micro levels.• Operators involvement is limited.

• Line efficiency is better understood • Micro control is the responsibility of team leader.• Team takes greater accountability and proactive roles in

productivity improvement.

• Organisational “Key Success Factors” are fully aligned with the individual objectives and Key Result Areas

• Team members become team leaders and are responsible for on-going continuous improvement initiatives both in efficiency and effectiveness.

• Team’s objectives fully aligned to Business objectives.

Characteristics

Direct involvement


Semi-directive

Tight control

Train and Develop


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Characteristics

Direct involvement


Semi-directive

Tight control

Train and Develop


All management and operational systems All management and operational systems and process, skills and competencies are and process, skills and competencies are aligned with strategy – driving strategic aligned with strategy – driving strategic behaviour into everyday decisions and behaviour into everyday decisions and

operations.operations.

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Advantages

• Increase in efficiency

• Better management and control of resources

• Facilitates organization wide alignment of business objectives

• Increases employee involvement and motivation

• Involves team leaders and operators to provide ideas for improvement

• Provides team members to learn to proactively solve problems (be part of the company

improvement initiatives)

• Team leaders and members (operators) can interact with QE, ME,Tool room and other

enabling functions to understand production from their perspective and vise-versa.

• Only team leader time needs to be allocated for meetings. (Away from production work)

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Team Leader: Role & Responsibility (R&R)

Team leaders would perform the following functions or have

these responsibilities..

– To manage team members to achieve output targeted

– To improve productivity

– To reduce overtime

– To improve product quality (rework and rejection)

– To ensure on-time delivery

– To problem solve within the group assigned

– Solicit improvement ideas/ suggestions from team members

– Turn ideas into actions/ operationalise improvement ideas

– Ensuring calibration of machines, jigs, fixtures and instruments

– Communicate team performance daily

– To motivate team members

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Migration Process - Stages

Definition Development Installation Audit

Migration Path

Assessment

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Assessment Stage

Assessment

Definition Development Installation AuditAssessment

Activities involved (Unit wise)• Definition of internal and external structure of the unit

• Detailed analysis of current processes and systems within the unit

• Structural analysis of team authority and responsibility

• Analysis of the decision making process

• Identify gaps in behavioral, skill and cultural alignment.

• Organizational fit assessment

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Definition Stage

Activities involved (Unit wise)• Define strategic focus areas

• Define team structure and layout

• Define team leader criteria and values

• Define team leader, supervisor & MO roles and responsibilities

• Define team’s measures of performance

• Redefine authority/responsibility matrix

Definition


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Definition Stage

Value

Addition

Cluster of similar equipments

Cluster of cell / individual cell

Team Structure: Possible Options

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Development Stage

Activities involved (Unit wise)• Select team leader

• Set team objectives

• Implement objectives & measures

• Track team CSF’s (Scorecard)

• Monitor & evaluate individual performance

• Develop action plans & supporting initiatives

Development


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Installation Stage

Activities involved (Unit wise)

• Train team leaders

• Train module owners and supervisors as change leaders

• On the job coaching and mentoring

• Develop and maintain Personal Development Plans

Installation


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Audit Stage

Activities involved (Unit wise)

• Compliance audit

• Understanding and usage audit

• Organizational alignment audit

• Culture change analysis

• Skills flexibility audit

Audit
