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Successful Plant Visit
Prepared By:
Hisham El-Tawil
Corporate Procurement
Innovation & Development Conference –
Alexandria 15 & 16 June 2014
Content
• Benefits of a successful Plant tour
• Reasons & types of plant tours
• The Visit framework
• Effective tools used in the plant tours
• Additional tips
• Conclusion & Recommendations
Innovation&Development
Conference-15&16June2014
2
“ALMOST EVERYONEWHO LEADS,WORK,OR
INTERACTSWITHA MANUFACTURINGCO. CAN
BENEFITFROM SEEINGA FACTORY
FIRSTHAND”
David M. Upton
Innovation&Development
Conference-15&16June2014
3
“TO THE TRAINEDEYE,EVENA QUICKPLANT
TOUR CAN REVEALA LOT ABOUT A COMPANY”
Eugene Goodson
Benefits of a Plant Tour
Senior Executives
• Assess competitors
• Company performance &
Strategy
• Understand a Site
Performance
Managers
• Review Suppliers’
qualifications
• Benchmark performance &
Practices
• Share Practices
Operators
• See other plants & Learn
• Application of learned lessons
Consultants
• Increase knowledge about the
clients
• Enhance experience
Innovation&Development
Conference-15&16June2014
4
Types of a Plant Tour
Innovation&Development
Conference-15&16June2014
5
To Learn
To
Teach
To
Assess
Learning Tour
• Focus on Practice
• Workflow
• Work-In-Process levels
• Keep an Open Mind
• Most learning is un-expected
• Visit plants unlike yours
Innovation&Development
Conference-15&16June2014
6
Teaching Tour
• When you go to bring knowledge to the visited party
• E.g. Supplier development
• Teaching in a different way
• Teaching by asking & challenging
• Raising the Morale of employees
Innovation&Development
Conference-15&16June2014
7
Assessment Tour
• Not to acquire knowledge but to evaluate a plant
• Supplier evaluation / plant acquisition
Innovation&Development
Conference-15&16June2014
8
Visit Framework
Visit Framework
Innovation&Development
Conference-15&16June2014
10
Strategic Role
• Competitive Advantage
• Plant /Company Strategy
Structural Alignment
• Right Equipment
• Hardware vs. Software
• ERP System
Day-to-Day Management
Improvement Path
Community
•Caretakers vs. Craftspeople
Systems
•WIP Level
•Machines Availability
Processes
•Scrap / Rework
•Products / Process Variability
Mini Case:
Textile Industry Strategy
Strategy: To Be
Responsive to
Customers’ needs KPI: Tons of Fibers
Produced / day
Innovation&Development
Conference-15&16June2014
11
KPI: Key Performance Indicators
Rapid Plant
Assessment RPA
A tool for effective plant visit
Rapid Assessment Process
Assign the
team
Train the team
•Training about Lean
•Training about RPA
Tools
•Plant tour in own
plant
Familiarize
with visited
plant
•Financial Report
•Website
•Industry Review
Use RPA Tools
•Tools Usage
•Data Presentation
& Visit reporting
•Recommendations
Innovation&Development
Conference-15&16June2014
13
RPA Tools
Innovation&Development
Conference-15&16June2014
14
RPA Tools
Rating Sheet
Questionnaire
Innovation&Development
Conference-15&16June2014
15
Yes
Lean
No
Waste
Innovation&Development
Conference-15&16June2014
16
RPA Categories
Innovation&Development
Conference-15&16June2014
17
RPA
Categories
Customer Satisfaction
Safety, Env., Cleanliness & Order
Visual Mgmt. System
Scheduling System
Use of Space & Material Flow
Inventory & WIP
Team Work & Motivation
Maintenance
Management of Complexity & Variability
Supply Chain Integration
Commitment to Quality
Customer Satisfaction
• Does Workers know their customers?
• How are they dealing with visitors?
• Ask Them: “Where does your product go next?”
Innovation&Development
Conference-15&16June2014
18
RPA Results Presentation
RPA Radar Chart
0
2
4
6
8
10
Customer Satisfaction
Safety, environment, cleanliness, &
order
Visual Management Deployment
Scheduling system
Product flow, space use & material
movement means
Inventory & WIP Levels
People teamwork, skill level, &
motivation
Equipment & tooling state &
maintenance
Ability to Manage Complexity &
Variability
Supply Chain Integration
Quality System Deployment
Series1
Innovation&Development
Conference-15&16June2014
19
Tips for a Successful RPA
• NEVER take notes during the tour
• Assign responsibilities among team members during the visit
 RPA categories
• Right down your notes immediately after the visit
• Team should meet immediately after the tour
• The tour provides visual information not in the documents.
• Wear a watch with a stopwatch.
• Assessing Waste = Improvement Opportunities
Innovation&Development
Conference-15&16June2014
20
Other Tools
• Material Control / Pull System Assessment Questionnaire
• Seven Waste Matrix
• Value Stream Mapping
Innovation&Development
Conference-15&16June2014
21
Visit Tips
What to wear?
• Weather
• Customs and Traditions
• Safety equipment at plant / Special shoes
• Dress Code
Innovation&Development
Conference-15&16June2014
23
Dress Code Samples
Innovation&Development
Conference-15&16June2014
24
Useful Dress Code Links
• http://www.dba-oracle.com/dress_code.htm
• http://www.ou.edu/oubigxii/Excellent%20Dress.pdf
• http://www.glamourdrops.com/posts/2013/07/12/dress-
codes-defined-from-white-tie-to-smart-casual
• http://blog.leadapparel.com/decoding-the-dress-codeis-your-
business-casual-smart-casual-or-formal/
Innovation&Development
Conference-15&16June2014
25
What after the tour?
• Send a thank you letter.
• Share photos & Media coverage.
• Report your experience
Innovation&Development
Conference-15&16June2014
26
Conclusion
• A plant tour can result in great benefit to the visitors
regardless its duration
• The reason(s) and the target of the visit must be
predetermined
• A visit framework should assess different managerial levels
• There are different effective supporting tools for Rapid
Assessment
• Training the visitors on RPA tools will result in maximized tour
benefits and consistent results
Innovation&Development
Conference-15&16June2014
27
Recommendations
• Preparing a 2-days workshop to train EZDK employees on
Rapid Plant Assessments (RPA) Tools
• Workshop can be customized according to managerial level
and/or function
• Prepare a booklet about plant tour and visits tips and
guidance
Innovation&Development
Conference-15&16June2014
28
References
• R. Eugene Goodson, TOOL KIT Read a Plant – Fast, Harvard
Business Review, May 2002.
• Upton D. & Macadam S., Why (and How) to take a Plant Tour,
EBSCO Publishing, 2003
Innovation&Development
Conference-15&16June2014
29
Thank You 30
Innovation&Development
Conference-15&16June2014

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Successful plant tour - CID Conference - Alexandria 2014

  • 1. Successful Plant Visit Prepared By: Hisham El-Tawil Corporate Procurement Innovation & Development Conference – Alexandria 15 & 16 June 2014
  • 2. Content • Benefits of a successful Plant tour • Reasons & types of plant tours • The Visit framework • Effective tools used in the plant tours • Additional tips • Conclusion & Recommendations Innovation&Development Conference-15&16June2014 2
  • 3. “ALMOST EVERYONEWHO LEADS,WORK,OR INTERACTSWITHA MANUFACTURINGCO. CAN BENEFITFROM SEEINGA FACTORY FIRSTHAND” David M. Upton Innovation&Development Conference-15&16June2014 3 “TO THE TRAINEDEYE,EVENA QUICKPLANT TOUR CAN REVEALA LOT ABOUT A COMPANY” Eugene Goodson
  • 4. Benefits of a Plant Tour Senior Executives • Assess competitors • Company performance & Strategy • Understand a Site Performance Managers • Review Suppliers’ qualifications • Benchmark performance & Practices • Share Practices Operators • See other plants & Learn • Application of learned lessons Consultants • Increase knowledge about the clients • Enhance experience Innovation&Development Conference-15&16June2014 4
  • 5. Types of a Plant Tour Innovation&Development Conference-15&16June2014 5 To Learn To Teach To Assess
  • 6. Learning Tour • Focus on Practice • Workflow • Work-In-Process levels • Keep an Open Mind • Most learning is un-expected • Visit plants unlike yours Innovation&Development Conference-15&16June2014 6
  • 7. Teaching Tour • When you go to bring knowledge to the visited party • E.g. Supplier development • Teaching in a different way • Teaching by asking & challenging • Raising the Morale of employees Innovation&Development Conference-15&16June2014 7
  • 8. Assessment Tour • Not to acquire knowledge but to evaluate a plant • Supplier evaluation / plant acquisition Innovation&Development Conference-15&16June2014 8
  • 10. Visit Framework Innovation&Development Conference-15&16June2014 10 Strategic Role • Competitive Advantage • Plant /Company Strategy Structural Alignment • Right Equipment • Hardware vs. Software • ERP System Day-to-Day Management Improvement Path Community •Caretakers vs. Craftspeople Systems •WIP Level •Machines Availability Processes •Scrap / Rework •Products / Process Variability
  • 11. Mini Case: Textile Industry Strategy Strategy: To Be Responsive to Customers’ needs KPI: Tons of Fibers Produced / day Innovation&Development Conference-15&16June2014 11 KPI: Key Performance Indicators
  • 12. Rapid Plant Assessment RPA A tool for effective plant visit
  • 13. Rapid Assessment Process Assign the team Train the team •Training about Lean •Training about RPA Tools •Plant tour in own plant Familiarize with visited plant •Financial Report •Website •Industry Review Use RPA Tools •Tools Usage •Data Presentation & Visit reporting •Recommendations Innovation&Development Conference-15&16June2014 13
  • 17. RPA Categories Innovation&Development Conference-15&16June2014 17 RPA Categories Customer Satisfaction Safety, Env., Cleanliness & Order Visual Mgmt. System Scheduling System Use of Space & Material Flow Inventory & WIP Team Work & Motivation Maintenance Management of Complexity & Variability Supply Chain Integration Commitment to Quality
  • 18. Customer Satisfaction • Does Workers know their customers? • How are they dealing with visitors? • Ask Them: “Where does your product go next?” Innovation&Development Conference-15&16June2014 18
  • 19. RPA Results Presentation RPA Radar Chart 0 2 4 6 8 10 Customer Satisfaction Safety, environment, cleanliness, & order Visual Management Deployment Scheduling system Product flow, space use & material movement means Inventory & WIP Levels People teamwork, skill level, & motivation Equipment & tooling state & maintenance Ability to Manage Complexity & Variability Supply Chain Integration Quality System Deployment Series1 Innovation&Development Conference-15&16June2014 19
  • 20. Tips for a Successful RPA • NEVER take notes during the tour • Assign responsibilities among team members during the visit  RPA categories • Right down your notes immediately after the visit • Team should meet immediately after the tour • The tour provides visual information not in the documents. • Wear a watch with a stopwatch. • Assessing Waste = Improvement Opportunities Innovation&Development Conference-15&16June2014 20
  • 21. Other Tools • Material Control / Pull System Assessment Questionnaire • Seven Waste Matrix • Value Stream Mapping Innovation&Development Conference-15&16June2014 21
  • 23. What to wear? • Weather • Customs and Traditions • Safety equipment at plant / Special shoes • Dress Code Innovation&Development Conference-15&16June2014 23
  • 25. Useful Dress Code Links • http://www.dba-oracle.com/dress_code.htm • http://www.ou.edu/oubigxii/Excellent%20Dress.pdf • http://www.glamourdrops.com/posts/2013/07/12/dress- codes-defined-from-white-tie-to-smart-casual • http://blog.leadapparel.com/decoding-the-dress-codeis-your- business-casual-smart-casual-or-formal/ Innovation&Development Conference-15&16June2014 25
  • 26. What after the tour? • Send a thank you letter. • Share photos & Media coverage. • Report your experience Innovation&Development Conference-15&16June2014 26
  • 27. Conclusion • A plant tour can result in great benefit to the visitors regardless its duration • The reason(s) and the target of the visit must be predetermined • A visit framework should assess different managerial levels • There are different effective supporting tools for Rapid Assessment • Training the visitors on RPA tools will result in maximized tour benefits and consistent results Innovation&Development Conference-15&16June2014 27
  • 28. Recommendations • Preparing a 2-days workshop to train EZDK employees on Rapid Plant Assessments (RPA) Tools • Workshop can be customized according to managerial level and/or function • Prepare a booklet about plant tour and visits tips and guidance Innovation&Development Conference-15&16June2014 28
  • 29. References • R. Eugene Goodson, TOOL KIT Read a Plant – Fast, Harvard Business Review, May 2002. • Upton D. & Macadam S., Why (and How) to take a Plant Tour, EBSCO Publishing, 2003 Innovation&Development Conference-15&16June2014 29