Lean Culture Now!

Lean Enterprise Software Solutions announce a major expansion to the reporting capabilities of LPA Admin. These modifications are being delivered to our clients at no additional cost. These changes assist management in analyzing their LPA data at a much deeper level than before. The added features should increase the effectiveness of their LPA program and assist them in continually improving quality. The changes to LPA Admin include:

· Added four additional criteria to build Custom Reports

· Designed and built an additional reporting system called Dashboard that allows users to build and save custom dashboard(s) with only the data items that they are interested in reviewing

· Users control time period of Dashboard Reports

· Ability to convert Dashboard Reports to an Excel format to allow users to utilize the data for charting and graphing in their company’s custom format

Additional Custom Report Criteria

Auditors, Custom Field #1 (Machine #), Custom Field # 2 (Tooling #), and Custom Field #3 (Operator) have been added to the Custom Report Builder. Note: in this exhibit the Custom Fields have been chosen as Machine #, Tooling #, and Operator. The three Custom Fields may be uniquely named by each LPA Admin client. Possible Custom Fields may be Machine #, Tooling #, Part #, Jig #, Line, Cell, Operator #, Spec #, Router, Job Order … etc.

Custom Field Data

Management team must determine when they want the data entered into the Custom Fields before training their auditors. They have two different options and each will give them different reporting capabilities. Option 1: Only enter data in the custom fields when an auditor finds a non-conformance. This will allow management to create unique reports for the custom fields that have non-conformances. Option 2: Have the data entered in the custom fields for every audit by the auditor. This would allow one to create unique reports for the custom fields for audits with and without non-conformances. Example: Management wants the capability to know how many audits were done on machine # A-784 last month. This would require the data to be entered using Option 2.

Auditors simply need to enter the Custom Field data per management’s criteria when entering the other audit data before selecting Save Changes.

Additional Custom Report Capabilities

Management may now build the six different custom reports using the additional filter criteria: Auditors, Custom Field #1, Custom Field #2, and Custom Field #3. The report timeframe may range from a single day up to 3 years and is determined by selecting dates on the Begin and End calendars or by choosing a date range from the Date Range Quick List dropdown . Like all of our reports, the user has the option to export the report in a number of different formats, to retain the information in their computer files, or provide it to outside interested parties.

Added Dashboard Report

A new webpage called My Dashboard was added for each user of LPA Admin to allow them to see their data in a different format. A Dashboard sorts the data and lists it for only the Parameters one chooses. This webpage will welcome each person by name and the information they save under My Saved Dashboards are dashboards that only appear on their webpage. The report timeframe may range from a single day up to 3 years and is determined by selecting dates on the Begin and End calendars or by choosing a date range from the Date Range Quick List dropdown .

Building Custom Dashboard Reports

A Custom Dashboard Report may be easily built by choosing the criteria from the Parameters using the dropdown menu and then selecting the Show in Dashboard that they want listed on your Dashboard.

Then select the Dashboard Type either Audits Planned, Completed, Missed or Non-Conformance and Build Dashboard.

Dashboard Reports In Excel Format

Custom Dashboard may be converted to an Excel format that allows users to utilize the data for charting and graphing in their company’s custom format.

Saved Dashboard will look like this when saved in Excel

One can make changes in Excel such as highlighting areas of interest.

Example of making a chart from the data above.

For more information about LPA Admin and it’s capabilities contact us at http://www.leanculturenow.com/Contact_Us.aspx

Jerry Yoder is an employee of Lean Enterprise Software Solutions

Make Plans to Attend Now - Training Dates and Locations:

• April 7^{th rd}              Fort Wayne, IN
• April 15^th               Bowling Green, KY
• April 29^th               Durham, NC
• May 6^th                  Detroit, MI 

Learn how to implement or improve one of the most powerful shop floor tools that has been proven to increase customer satisfaction by improving product quality and reducing waste.  Layered Process Auditing is an effective way to drive process and facility culture changes that reduce scrap, warranty issues, and costs.   Our Quality expert will coach participants through the process of building a Layered Process Auditing System or improving an existing LPA program to be more effective.  

Agenda:

•  Review Layered Process Audit Overview and Concepts
•  Identify Benefits and Roadblocks
•  Define What Supports an Effective LPA Program
•  Examine LPA Implementation Process Map
•  Discuss the Leadership’s Responsibilities
•  Identify High Risk Areas
• Discuss the Difference Between Process Control and Mistake Proof Verification Questions and Audits
•  Best Practice Audit Questions Examples
•  Question Development - Breakout Session
•  Identify Reporting Needs by Internal and External Customers
•  Review How to Document a LPA Program
•  Develop a LPA Audit Flow Diagram
•  Determine the Organizational Structure
•  Identify Training Needs for the Organization
•  Ways To Evaluate the Effectiveness of LPA

 Register by Visiting:  http://www.leanculturenow.com/Class_Registration.aspx

Another option would be to have the training held at your facility.  Get in touch with us if you would like a quote for onsite training and eliminate your travel expenses.

 

Class Name: LPA Implementation Training  

Price: $395 per person includes training materials and lunch (room not included) Reservation and logistic information will be sent to you upon receipt of class registration Special room rates available for early registration participants.

Jerry Yoder is an employee of Lean Enterprise Software Solutions

Make Plans to Attend Now - Training Dates and Locations:

• Feb. 18^th              Dallas, TX
• March 4^th             Chicago, IL
• March 23^rd          Toronto, ON
• April 15^th             Bowling Green, KY
• April 22^nd            Boston, MS
• May 6^th                Detroit, MI 

Learn how to implement or improve one of the most powerful shop floor tools that has been proven to increase customer satisfaction by improving product quality and reducing waste.  Layered Process Auditing is an effective way to drive process and facility culture changes that reduce scrap, warranty issues, and costs.   Our Quality expert will coach participants through the process of building a Layered Process Auditing System or improving an existing LPA program to be more effective.  

Agenda:

•  Review Layered Process Audit Overview and Concepts
•  Identify Benefits and Roadblocks
•  Define What Supports an Effective LPA Program
•  Examine LPA Implementation Process Map
•  Discuss the Leadership’s Responsibilities
•  Identify High Risk Areas
• Discuss the Difference Between Process Control and Mistake Proof Verification Questions and Audits
•  Best Practice Audit Questions Examples
•  Question Development - Breakout Session
•  Identify Reporting Needs by Internal and External Customers
•  Review How to Document a LPA Program
•  Develop a LPA Audit Flow Diagram
•  Determine the Organizational Structure
•  Identify Training Needs for the Organization
•  Ways To Evaluate the Effectiveness of LPA

 Register by Visiting:  http://www.leanculturenow.com/Class_Registration.aspx

Class Name: LPA Implementation Training  

Price: $395 per person includes training materials and lunch (room not included)  Reservation and logistic information will be sent to you upon receipt of class registration Special room rates available for early registration participants

Jerry Yoder is an employee of Lean Enterprise Software Solutions

Learn how to implement or improve one of the most powerful shop floor tools that has been proven to increase customer satisfaction by improving product quality and reducing waste.  Layered Process Auditing is an effective way to drive process and facility culture changes that reduce scrap, warranty issues, and costs.

Our Quality expert will coach participants through the process of building a Layered Process Auditing System or improving an existing LPA program to be more effective.

Agenda:

• Review Layered Process Audit Overview and Concepts
• Identify Benefits and Roadblocks
• Define What Supports an Effective LPA Program
•  Examine LPA Implementation Process Map
• Discuss the Leadership’s Responsibilities
• Identify High Risk Areas
• Discuss the Difference Between Process Control and Mistake Proof Verification Questions and Audits
• Best Practice Audit Questions Examples
• Question Development - Breakout Session
• Identify Reporting Needs by Internal and External Customers
• Review How to Document a LPA Program
• Develop a LPA Audit Flow DiagramDetermine the Organizational Structure
• Identify Training Needs for the Organization ü  Ways To Evaluate the Effectiveness of LPA   

Training Date: January 13, 2010 Class will be held in Bowling Green, Kentucky at the Baymont Inn & Suites 65 Three Springs Road.

To Register: go to                                                                                                                                            

http://www.leanculturenow.com/Class_Registration.aspx

Class Name: LPA Implementation Training  

Price: $395 per person includes breakfast and lunch (room not included)Reservation and logistic information will be sent to you upon receipt of class registration Special room rates of $54.00 + tax available for participants 

Jerry Yoder is an employee of Lean Enterprise Software Solutions

Learn how to implement or improve one of the most powerful shop floor tools that has been proven to increase customer satisfaction by improving product quality and reducing waste.  Layered Process Auditing is an effective way to drive process and facility culture changes that reduce scrap, warranty issues, and costs.   

Our Quality expert will coach participants through the process of building a Layered Process Auditing System or improving an existing LPA program to be more effective.  

Agenda:

•  Review Layered Process Audit Overview and Concepts
•  Identify Benefits and Roadblocks
•  Define What Supports an Effective LPA Program
•  Examine LPA Implementation Process Map
•  Discuss the Leadership’s Responsibilities
•  Identify High Risk Areas
• Discuss the Difference Between Process Control and Mistake Proof Verification Questions and Audits
•  Best Practice Audit Questions Examples
•  Question Development - Breakout Session
•  Identify Reporting Needs by Internal and External Customers
•  Review How to Document a LPA Program
•  Develop a LPA Audit Flow Diagram
•  Determine the Organizational Structure
•  Identify Training Needs for the Organization
•  Ways To Evaluate the Effectiveness of LPA  

Training Date: Oct. 28, 2009

Class to be held in Detroit, MI at the Marriot 30559 Flynn Drive Ramulus, MIJust a shuttle bus ride away from Detroit Metro Airport  

To Register: go to http://www.leanculturenow.com/Class_Registration.aspx  

Class Name: LPA Implementation Training  

Price: $395 per person includes breakfast and lunch (room not included)

Reservation and logistic information will be sent to you upon receipt of class registration Special room rates of $119.00 + tax available for participants through their website www.marriottdetroitairport.com 

Jerry Yoder is an employee of Lean Enterprise Software Solutions

Learn how to implement or improve one of the most powerful shop floor tools that has been proven to increase customer satisfaction by improving product quality and reducing waste.  Layered Process Auditing is an effective way to drive process and facility culture changes that reduce scrap, warranty issues, and costs. 

Our Quality expert will coach participants through the process of building a Layered Process Auditing System or improving an existing LPA program to be more effective.

 

Participants will:

ü  Review Layered Process Audit Overview and Concepts

ü  Identify Benefits and Roadblocks

ü  Define What Supports an Effective LPA Program

ü  Examine LPA Implementation Process Map

ü  Discuss the Leadership’s Responsibilities

ü  Identify High Risk Areas

ü  Discuss the Difference Between Process Control and Mistake Proof Verification Questions and Audits

ü  Best Practice Audit Questions Examples

ü  Question Development - Breakout Session

ü  Identify Reporting Needs by Internal and External Customers

ü  Review How to Document a LPA Program

ü  Develop a LPA Audit Flow Diagram

ü  Determine the Organizational Structure

ü  Identify Training Needs for the Organization

ü  Ways To Evaluate the Effectiveness of LPA

 

Training Date: Sept. 16, 2009

Class to be held in Chicago, IL at the Holiday Inn Itasca

15 min. from Chicago O’Hare Int’l Airport

Located near Woodfield Mall

Course Time: 8:00 a.m. – 4:00 p.m.

 

To Register: go to www.lpaadmin.com Contact Us

 

Price: $395 per person includes breakfast and lunch

Reservation and logistic information will be sent to you upon receipt of registration

Special room rates of $85.00 + tax available for participants

 

Jerry Yoder is an employee of Lean Enterprise Software Solutions

Many companies are finding an increased number of non-conformances as they continually modify their audit questions to focus on the high risk processes in their facilities. This increases the opportunity to improve quality, but does not guarantee you progress. To really drive your organization to achieve single digit PPM and eventually Zero Defects your management team must have good problem solving skills. Identifying non-conformances is a great first step to show you what, where, and when your problems are occurring. The next step is to determine immediate corrective action. This is like step 3 of a Global 8-D process: Develop an Interim Containment Action. This action should protect the customer (internal or external) 100% from the effect of the problem. It should be verified, easy to implement, and cost effective. The auditor or area management must also determine if containment actions are required for product made prior to the finding to protect the customer from a quality spill. Many companies do not realize that the containment action (example: reject prior 8 hour of production) needs to be part of the corrective action. Receiving rejections for products that were made a short time prior to when the non-conformance was found is a good sign that your containment activities were not effective. Implementing the immediate corrective action and containment action must be well documented within the requirements in your Quality Management System. This may require writing a deviation to change the process for a period of time in addition to documenting your actions in your LPA tracking system. If a management person is unable to identify a suitable immediate corrective action, the best action may be to shut down the process and contain the product produced prior to the finding. Effective LPA programs require an upper level management person who has profound knowledge in the non-conformance process area to review and approval the corrective action and containment activities within a short period of time. Management may modify the corrective action or containment activities to improve the protection to keep the customer from receiving poor quality products. Validation of the final immediate corrective action and containment activities will be done by your customers. They will notify you if they receive a quality spill.

The total cost of quality is the combined sum of the costs in these areas:

Scrap

Rework

Use of excess materials (i.e. Off-cuts)

Equipment breakdowns

Preventive maintenance

Yield below quote

Productivity below quote

Customer rejections

Returned goods and return freight

Warranty

Quality department (wages, equipment, & overheads)

Lab department (wages, equipment & overheads)

All mistake-proofing devices

All measurement devices and gages

Dock audits

Third party audits

Data collection systems

An effective layered process audit program will improve the overall quality of your organization, while reducing your company’s Total Cost of Quality.

A Good LPA System, implemented in the correct areas, can be an effective tool to use toward achieving Zero Defect production. With the right focus on high-risk processes, factors which could lead to defective products can be closely monitored. An effective LPA system quickly identifies variations. If audits occur regularly enough, these variations can be corrected before bad product is manufactured, or at the very least before defective products are shipped to customers. Catching defects before they are shipped or even before they happen provides obvious opportunities for cost savings. The question is, how can an LPA system help achieve this? Timing and containment are the key.

Timing 

The first element of timing is obviously the overall LPA schedule. Layer One audits- audits performed by the first-line of defense in your LPA system- should be performed very regularly. Generally, it is a good idea to perform these audits at least once per shift. However, individual circumstances may require more frequent auditing. Higher layers should also perform the audits on a fairly regular basis, but this is of secondary concern to us now, so we will leave that topic for another time.

The second element of timing involves reaction to non-conformances. When an auditor discovers conditions outside of audit parameters, the initial response should be immediate and decisive. Auditors must be trained about the types of reactions which are expected of them and be given the authority to do what is necessary to prevent potentially defective products from moving down the line and out the door. Whether this involves calling maintenance immediately to perform repairs or shutting down the line and moving product or parts to quarantine, the reaction should occur at the time the non-conformance is discovered. The more time that elapses before corrective action, the likelier defects are to move through production and out the door. Correcting symptoms quickly saves scrap, rework and sorting, and it reduces the possibility of outside rejections.

Containment

It is important that non-conformances discovered during an audit are not simply documented for later review. Corrective action should begin immediately and should almost always include containment action. Because layered audits are meant to focus on critical process parameters that are likely to lead to defective product, discovering variation outside of allowed tolerances means there is a chance defective product has already been produced. If there is reason to believe that non-conforming product is moving downstream, a timeframe for suspect product should be established, and product produced during that timeframe should be physically isolated from production flow. Inspection and sorting can be discussed and completed from that point on. There is always time later to review what was done and improve. Training your auditors to perform audits is a start, but it is not enough. You must also make sure they know what actions to take when problems arise. 

The key to successfully preventing internal and customer rejections is acting swiftly when a problem is identified and ensuring product that may be affected is set aside immediately. Everything after the initial containment activity can happen at whatever pace management chooses, but containment has to happen right away.