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OPEREX — Operational Excellence
Overview
What is OE
Operational Excellence (OE)
The OPEREX house — what OE covers
Organization and rhythm
Operations and the asset team — the integrated operating unit
Operations' role in the asset team
The maintenance role in asset teams
Technology's role in the asset team
Support functions in the asset team
The asset team's operating rhythm — daily, weekly, monthly
Steering and deployment
Vision workshop: montage to action
OGSM strategy deployment
Policy Deployment (Hoshin Kanri) and catchball — strategy breakdown by consensus
MOS — Management Operating System
Lean & Process Improvement
Overview
Foundations
Lean basics — what is Lean, and what are its principles?
Toyota Production System (TPS) — the origin of Lean and its adaptability
The five Lean principles: Value, Value Stream, Flow, Pull, Perfection
Voice of the Customer (VOC) — customer value as a compass
Flow and lead time — Ohno's view of time
True North (ideal state) and the current–target state gap
The House of Lean (TPS House)
The Three Lenses of Lean: Operating System, Management Infrastructure, Mindsets & Behaviours
Operating System
Muda, Mura, Muri — the three inhibitors of flow (Waste, Variability, Inflexibility)
Muda — the 8 wastes (TIMWOODI)
Mura (unevenness / variability)
Muri (inflexibility)
The three types of activity (value vs. waste) and the 5 questions for a process step
Value stream map (VSM / MIFA)
The VSM toolbox: the 7 detailed mapping tools and Big Picture Mapping
Pull system: push vs. pull, heijunka and kanban
Kanban — the signaling tool of the pull system
Standardized work (Standard Work)
SMED — quick changeover (Single Minute Exchange of Die)
Jidoka — built-in quality and autonomation (Andon)
Poka-yoke — mistake-proofing
TPM — Total Productive Maintenance
5S methodology
Management Infrastructure
Management Infrastructure (MI) — the five elements of the Lean management system
Feedback — principles, good vs. poor, a structured process
KPI — the definition of the key performance indicator and the marks of a good one
KPI cascade — breaking targets down across organizational levels (OGSM What/How)
KPI / PI / I — the indicator hierarchy and the intervention tree
Capability building (skills matrix)
Production Excellence
Overview
Foundations
Production reliability program
Housekeeping and maintenance
Autonomous maintenance
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Production Excellence
Foundations
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Production reliability program
Housekeeping and maintenance
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Autonomous maintenance