ISILeanAssessmentwithGraphv1.1

8/12/2019 ISILeanAssessmentwithGraphv1.1

1/5

INDUSTRIAL SOLUTIONS

LEAN A SSESSMENT SCORECARD

Communication Visual Systems and Workplace OrganizationPoints Score Points Score

1 Plant Management communicates with alllevels of the

organization on topics regarding organization goals and

objectives at least twice per year.

0 1 2 3 4 5 3

1 The Manufacturing plant and support areas are generally clear

of unnecessary materials, items or scrap. Isles are clear of

obstructions.

0 1 2 3 4 5 3

2Employees are able to accurately describe the organization'sgoals and how their job contributes to the achievement of those

goals.

0 1 2 3 4 5 1

2The plant floor has lines that distinguish work areas, paths andmaterial handling isles.

0 1 2 3 4 5 2

3 Employees receive feedback through a formal process

concerning problems found in downstream processes or from

the customer.

0 1 2 3 4 5 2

3 All employees are aware of good housekeeping practices and

operators consider daily clean up and put away activities as part

of their job.

0 1 2 3 4 5 4

4 Management encourages production employees to work in

groups to address performance, quality or safety issues.

0 1 2 3 4 5 2

4 There is a place for everything and is everything in its place.

Every needed item, tool, material container or part rack is

labeled and easy to find.

0 1 2 3 4 5 25 Employees at the shop floor level understand and use common

performance metrics to monitor and improve the production

processes.

0 1 2 3 4 5 1

5 Display boards containing job training, safety, operation

measurables, production data, quality problems and

countermeasure information are readily visible at each

production line or process and are updated continuously. 0 1 2 3 4 5 36 Problems in the production process are detected and

investigated within ten (10) minutes of the first occurrence.

0 1 2 3 4 5 2

6 Check sheets describing and tracking the top quality defects

are posted and are up to date at each work station.

0 1 2 3 4 5 1

7 The concept of Value Stream Mapping is understood and all

product famalies have been mapped and are physically

segregated into the like process streams.

0 1 2 3 4 5 2

Total Score 13 Total Score 15

Communication Category Score = Total/35 37% Visual Systems Category Score = Total/30 50%

Operator Flexibility Points Score Continuous Improvement Points Score1 Operators are given formal training before doing a job on their

own. Few defects or production slowdowns are attributable tonew or inexperienced operators.

0 1 2 3 4 5

1 There is a designated champion and a clearly communicated

strategy for continuous improvement in the plant with thenecessary resources, organization and infrastructure in place to

support the process. 0 1 2 3 4 5

2 Product/Component travel distances have been measured,

analyzed and reduced by moving equipment and work stations

closed together.

0 1 2 3 4 5

2 There is a formal suggestion process in place to solicit ideas for

improvements from all employees and to recognize their

participation.

0 1 2 3 4 5


2/5

LEAN ASSESSMENT SCORECARD

Mistake Proofing (Poka Yoke) Points Score SMED/Quick Changeover Points Score1 Employees have been trained in the basis of mistake proofing and there is

a team responsible for analyzing production defects and identifying mistake

proofing opportunities.

0 1 2 3 4 5

1 Changeovers are scheduled in advance and communicated

to inform all workers that these events are on that day's

schedule.

0 1 2 3 4 5

2 Mistake proofing devices and methods have been implemented or are

being developed to eliminate the top production defects for each work area

in the plant.

0 1 2 3 4 5

2 Changeover teams are in place and have received training

on changeover time reduction procedures and are actively

improving change over methods.

0 1 2 3 4 53 Parts, products and components have been analysed to identify design

opportunities to eliminate waste and improve productivity.

0 1 2 3 4 5

3 Changeovers are done frequently and typically take less

than 10 minutes from last good part of the last run to first

good part of the next run.

0 1 2 3 4 5

4 Operators are empowered to stop the line when a defective unit is found or

when they cannot complete their process according to the SOP.

0 1 2 3 4 5

4 Changeover time is visibly tracked and posted at each work

station where changeovers are performed.

0 1 2 3 4 5

5 Manual processes or tasks have been equipped with mechanical checks to

aid human judgement whenever possible.

0 1 2 3 4 5

5 Changeover procedures are standardized and repeated in

other areas of the plant. Standard procedures and

checklists are visible and followed0 1 2 3 4 5

6 Equipment and processes are equipped with call(andon) lights or signals

that bring attention to situations requiring assistance with a problem or the

replenishment of supplies.

0 1 2 3 4 5

6 Special tools and equipment have been developed and

implemented to reduce the time and labor involved in the

changeover process.

0 1 2 3 4 5


Mistake Proofing Category Score = Total/30 0% SMED Category Score = Total/30 0%

QualityPoints Score

Supply ChainPoints Score

1 Zero defects from suppliers is a policy

0 1 2 3 4 5

1 Suppliers are involved in continuous improvement efforts

with the company

0 1 2 3 4 5

2 The company quality system is effectively implemented and compliant with

a national standard such as ISO-9000

0 1 2 3 4 5

2 Performance to delivery policy (on-time) is better than 98%

0 1 2 3 4 5

3 FMEA is in place(Feedback, rootcause, etc.)

0 1 2 3 4 5

3 Quality performance of the suppliers exceeds 98%

0 1 2 3 4 5

4 Material Review Board/Discrepant material disposition is in place

0 1 2 3 4 5

4 Electronic communications with suppliers is used to trigger

release of supplies under a kanban system

0 1 2 3 4 5


3/5

LEAN ASSESSMENT SCORECARD

Balanced Production Total Productive Maintenance1 There is an effort to level production schedules by requiring

suppliers to schedule frequent, smaller deliveries, over the

period.

0 1 2 3 4 5

1 Maintenance team managers and workers have been

trained in the basics of TPM

0 1 2 3 4 5

2 Changeovers in production are made to support the concept

of running to demand for all products, and not to support

long production runs, WIP inventory buffers, or daily shortship emergencies, etc. 0 1 2 3 4 5

2 Machines have all necessary safety guards in place. Safety

devices are in working order and equipment is locked out

immediately when broken down or when otherwiseappropriate. 0 1 2 3 4 5

3 Takt time is known by all associates and determines the

pace of production in the plant.

0 1 2 3 4 5

3 Preventive maintenance activity lists are posted in work

areas and item completions are tracked over t ime.

0 1 2 3 4 5

4 Production is facilitated through Value Stream Managers

0 1 2 3 4 5

4 Accurate and visible maintenance records are kept up to

date and posted nearby for all production and support

equipment.

0 1 2 3 4 5

5 Processes on production lines or in cells are balanced orleveled so the difference between cycle times of linked

processes is negligible.

0 1 2 3 4 5

5 Preventive maintenance activities are focused on increasingprocess utilization and minimizing cycle time variation.

0 1 2 3 4 5

6 When demand volume changes, production processes are

re-balanced or redesigned to flex up or down the process

cycle times to correspond to the new Takt time.

0 1 2 3 4 5

6 Preventive maintenance responsibilities are defined for both

maintenance and production workers.

0 1 2 3 4 5

7 When demand volume changes long term, supermarket and

POUS levels are adjusted to meet the new Takt time.

0 1 2 3 4 5

7 Time is allowed in the daily production schedule for workers

to perform their preventive maintenance and cleaning

duties.

0 1 2 3 4 5


Balanced Production Category Score = Total/35 0% Total Productive Maintenance Score = Total/35 0%

Pull Systems Standard Work1 Each Manufacturing cell, line or process has displayed,

visually, the target and actual hourly output as well as theshifts production requirements and timing.

0 1 2 3 4 5

1 Standard operating procedures have been developed for

each process or cell and are used to train operators.

0 1 2 3 4 5

2 All production managers and supervisors have been trained

in the principles and implementation of shop floor material

pull systems.

2 Every production process has its SOP posted within view of

the worker performing the process.


4/5

Accounting Systems Engineering1 Accounting personnel are fully aware and trained in lean

manufacturing principles

0 1 2 3 4 5

1 Engineering personnel are aware, involved and trained in

lean principles

0 1 2 3 4 5

2 Accounting personnel are actively involved in waste

elimination efforts throughout the company and participate

in process improvement activities at least 50% of the time

0 1 2 3 4 5

2 Systematic efforts are in place to reduce product variation

and the number of items (part numbers) in the system

0 1 2 3 4 5

3Accounting is organized along value streams and reports

results along value streams

0 1 2 3 4 5

3Engineering has organized its activities along value

streams

0 1 2 3 4 5

4 Accounting processes are organized visually and the

workplace shows evidence of visual indicators to control

the status of work flow

0 1 2 3 4 5

4 Engineering processes are organized visually and the

workplace shows evidence of visual indicators to show

status of work

0 1 2 3 4 5

5 Accounting delivers information and performance reports

that support the lean conversion and do not cause

managers to make the wrong decisions

0 1 2 3 4 5

5 Engineering processes have been balanced to create flow

and reduce lead time within the Engineering department

0 1 2 3 4 56 Performance measures such as lead time and velocity are

used to measure the department and establish goals for

continuous improvement

0 1 2 3 4 5

6 Engineers routinely go to the location of a problem in

production to assess the actual situation and communicate

with the production operators to obtain their input.

0 1 2 3 4 5

7

0 1 2 3 4 5

7 Performance measures such as lead time and velocity are

used to measure the department and establish goals for

continuous improvement

0 1 2 3 4 5


Accounting Systems Category Score = Total/30 0% Engineering Category Score = Total/35 0%

Performance Measurement/Internal Customer Communication1 Numerous and detailed financial reports have been

replaced by a few key measures of enterprise performance

0 1 2 3 4 5

1 There is a standard system in place for collecting customer

satisfaction information and data

0 1 2 3 4 5

2 Traditional cost accounting measures and

individual/department efficiency measures have been

replaced by value stream performance measures

0 1 2 3 4 5

2 Customer requirements are identified and communicated

throughout the supply chain

0 1 2 3 4 5

3 Performance results are communicated openly to all

employees and are visually posted to show status and

progress

0 1 2 3 4 5

3 Customer complaints are handled the same day they are

received in under 2 hours

0 1 2 3 4 5


5/5

INDUSTRIAL SOLUTIONS, INC

Lean Assessment Summary and Graph

Category ScoreCommunication 37%

Visual Systems and Workplace Organization 50%

Operator Flexibility 0%

Continuous Improvement 0%

Mistake Proofing (Poka Yoke) 0%

SMED/Quick Changeover 0%

Quality 0%

Supply Chain 0%

Balanced Production 0%Total Productive Maintenance 0%

Pull Systems 0%

Standard Work 0%

Accounting Systems 0%

Engineering 0%

Performance Measurement 0%

Customer Communication 0%

0%

10%20%

30%

40%

50%

60%

Communication

VisualSystems

andWorkplace

Organization

Operator

Flexibility

Continuous

Improvement

MistakeProofing

(PokaYoke)

SMED/Quick

Changeover

Quality

SupplyChain

Balanced

Production

TotalProductive

Maintenance

PullSystems

StandardWork

Accounting

Systems

Engineering

Performance

Measurement

Customer

Communication

Rating

Category Ratings

Enterprise Characterist ic

Consider the overall average of all categories

0%-20% Traditional Manufacturing

20%-40% Getting started with Lean

40%-60%Lean Progress

60%- 80% Value Stream/ lean focus/ integrated supply chain

80% - 90% LeanContinuous Improvement Culture

> 90% World Class Lean Enterprise

Documents

ISILeanAssessmentwithGraphv1.1