Lead a productivity improvement project on the fit-out line

What is going on

Only 88 per cent of builds are leaving the fit-out line on schedule and rework hours per build have climbed to 2.1. The General Manager has asked the Production Planning and Support Manager to run an improvement project and you have been asked to lead the crew through it. Known issues include a back order on amber marker lights that has stopped work twice, a missing panel lifter that contributed to a hand injury, repeat marker light faults, and a second shift starting on 21 September that will double the number of people using the same tools and stores. The customer quality audit on 14 October will look at how the business manages repeat problems. The proposal and trial plan are due in two weeks.

Your brief

Gather and analyse the data from the work orders and non-conformance register, involve the crew in identifying causes, propose improvements with measurable benefits, plan a trial and prepare the proposal and a customer facing explanation of how delivery reliability will improve.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

• Extract the fit-out stage data from the Work Orders and Build Tracker and the fit-out non-conformances from the register, and summarise the delays, rework and stock outs with numbers.
• Plan and record a crew problem solving session using the Toolbox Talk Record Template, listing the causes the crew identified and how you kept the discussion constructive.
• Build a cause and effect diagram or five whys analysis for the top two causes, using the stock, maintenance and safety records to support each cause.
• Complete a Continuous Improvement Proposal Template for the highest value improvement, with current state data, the proposed change, expected benefit, cost and a trial plan.
• Check the Plant Maintenance and Calibration Requests and the Materials and Components Stock register and identify what equipment and stock actions must be in place before the second shift starts.
• Write a short plan for how you will lead the crew through the trial, including how you will communicate, measure and respond to resistance.
• Draft a customer service note for Statewide Fleet Leasing explaining what is being done to improve delivery reliability on their remaining curtainsider builds, without making promises the trial has not proven.

What someone in this role would produce

• Data summary of fit-out delays, rework and stock outs
• Crew session record and cause analysis
• Completed Continuous Improvement Proposal
• Pre-second shift equipment and stock action list
• Leadership plan and customer service note