FGS Overview Presentation
Lean in Operations
Title: Non Exempt Time Keeping Process
Operations/
Station
Problem
HR Payroll
Compliance to new
corporate policy requires
excessive labor and risk of
non compliance
After
% Improved
Removed muda from the
process by eliminating NVA Metrics
process steps and creating (UOM)
a poka yoke to ensure
compliance with federal
and local authorities
CT Hrs
Results
Before
Customer
Action Taken
176
137
22%
Savings
Hard
(USD/
month)
Americas Sites
Tools Used
X
Goals
Defect x1/10
Lead-Time x1/2
Inventory x1/2
Scrap x1/10
X
Productivity x2
Space x1/2
Before Kaizen
Soft
(USD/
month)
$27K
Inventory /
AR/AP
(USD/
month)
Installed permanently on line
- Implemented Standard
Work
Implementation Start Date
1-May-10
100% Implementation Plan
1-Jun-10
Potential Savings/Month
after 100% Implementation
Lean
Six Sigma
Method for Sustaining
Hard
Soft
Inventory /
AR/AP
US$0
US$27K
US$0
After Kaizen
1
Lean in Operations
Title: Time Of Management Process Improvement
2
Lean in Office –
Title: OJT Database
Over Processing: Repeated manual entry of data
Operations/
Station
Dallas
Operations
Customer
NA
Problem
Action Taken
FlexTalent is not conducive
for entering/storing OJT
training
- Repeated Data Entry:
Must complete various
templates in order to upload
the training records (course
ID template & 4tab upload
template)
Tools Used
X
Lean
X
Results
Method for Sustaining
Savings
Create a user friendly
database to store the sites
OJT training
- System pulls the course
info directly from the
Course Catalog
- No template is needed to
enter the data (single entry)
X
Defect x1/10
Metrics
(UOM)
Bef ore
Af ter
%
Improve
d
Steps
16
5
69%
Cycle
Time
26
5
81%
Hard
(USD/
month)
Sof t
(USD/
month)
Net Working
Capital ( NWC)
Reduction
(USD/month)
Training
Implementation Start Date
11/09
100% Implementation Plan
11/09
735
Lead-Time x1/2
Inventory x1/2
Scrap x1/10
Productivity x2
Space x1/2
Potential Savings/Month
af ter 100% Implementation
GOALS
Six Sigma
Hard
US$0.74K
X
Before Kaizen
Steps = 16
Review
Course ID
referenced on
Training
Records
YES
Is Course ID
listed in Course
Catalog?
Enter course
number on
training
record.
Time = 26 min.
Enter Training
Record on
template to
upload
records in Flex
U
Download
template
NO
Add Course ID
to Texas Course
Catalog
Enter
employee’s
email address
or 32 digit SID
number
Complete Event
Template, upload
in Flex U
FlexTalent
Process Flow
YES
Log into Flex
U, verify
instructor’s
name is listed
Flex Email?
Supervisor
submits
training record
to training
coordinator
Review
Course ID
referenced on
Training
Records
Is instructor
listed and is
email
available?
NO
Upload
template in
User Upload
Tool and
validate
Enter
information
manually
Steps = 5
Is Course ID
listed in Course
Catalog?
YES
Enter course
number on
training
record.
NWC
Reduction
US$XXK
Time = 5 min.
Enter data in
Sharepoint OJT
database. (Data may
be entered by
supervisor or training
coordinator)
NO
NO
Enter
employee’s
Workday ID,
Legacy ID or
Agency ID
Upload Event
Template and
check progress
Verify data
entered is correct.
Ensure no
conflicts exist.
(Training, date,
time, location)
After Kaizen
Verify correct
User ID for
employees is
entered.
Soft
US$XXK
SharePoint
Process Flow
Add course ID to
Texas Course Catalog
View details,
review the Roster
and Session to
ensure successful
upload
YES
Click submit button.
YES Roster details should
Upload
list employee’s user
successful?
ID. Session details
should list session’s
NO
ID.
Run report of
selected sample of
events, verify data
was entered in
employee’s
transcript.
YES
Records
found?
Initial and date
training report.
Scan training
record and
create file name
referencing that
specific training.
Enter data
(data
automatically
loaded in
system)
Initial training
record hard
copy and list
date entered
Scan record to
desk top to
rename
document to
that specific
training.
Retain file on the G
drive:\Training\
Training Dept Use
Only\Training Rosters
– Filing. Place in the
appropriate month/
year.
Dispose of
paper copy.
NO
Investigate and
correct issue
Retain file on the G drive:\
Training\Training Dept
Use Only\Training Rosters
– Filing. Place in the
appropriate month/year.
NO
File the
original.
Is file
available?
YES
Create File
Site Yokoten
Implementation Status:
Guide: 81% ~ 100%
3
Lean in Office – Optimize re-hiring process
Title: Reduce the LT for training
4
Lean in Office – Human Resources
Title: Attached Worker UI Process Improvement
After Kaizen
Before Kaizen
Work now
completed by
HRSS
Manual
Process
by local
HR OPS
Site Yokoten
Implementation Status:
Guide: 81% ~ 100%
Defect
Reduction
59%
Reduction
in Process
Time
5
Lean in Office – Optimize Re-hiring Process
Title: Reduce Re-hire Recruiting LT
6
Lean in Office – Human resources
Title:Medical Leave Reduction Improvement
Counseling Procedure / Skip Level Meeting / Help Desk
Operations:
Problem
1. No ownership
& coordination.
2. Insufficient
Plant 2
learning &
development
program.
3. Insufficient
Customer:
awareness of the
availability of
Cisco
Tools Used specialist
services.
Lean
Action Taken
1. Counseling
Procedures.
2. Skip Level
Meetings.
3. Improved Help
Desk.
Before Kaizen
Metrics
(UOM)
MC
Days
Man
days
Loss
(USD)
Six Sigma
Method for
Sustaining
Results
Hard
Soft
HR & Operations
Savings Savings review on
(USD/
(USD/ periodic basis
% Improved month) month) (quarterly)
Before
After
1047
673
36%
USD
39,897
USD
27,705
31%
USD
12,193
After Kaizen Learning & Development
Material includes procedure
Savings
of USD
12,193 /
mth.
NIL
Site Yokoten
Implementation Status:
Guide: 81% ~ 100%
7
Lean in Office
Title : Recruitment Process Improvement
Operations:
Problem
Action Taken
Metrics
(UOM)
HR
1) No visibility of
Introduce visual board
recruitment status in HR office to monitor
in HR Office and
recruitment status
need time to
Customer:
track and update
record sheet on
Internal
Requester hiring status
Tools Used
Lean
X
Man
hour/mth
(min)
Before After
%
Improved
$ Soft
$ Hard
saving
saving
USD/mt
USD/mth
h
Establish
standard work
Implementation Start Date
288
24
92%
Saving of 44
$44 / Month
10/08
100% Implementation Plan
10/08
Potential Savings/Month
af ter 100%
Implementation
Hard
US$XXK
Six Sigma
Before Kaizen
1
Method for
Sustaining
Results
Soft
US$44
After Kaizen
2
Hiring Aging
Green – Day 1 to 20
Yellow – Day 21 to 30
Retrieve Manpower Request (MR) file
3
Red – Day > 30
Search for outstanding ‘Manpower
Request Document’
Visual Card: Indicate # of
vacancy & Dept request.
4
Separate Ageing Request
Candidate accepted job
offer: Targeted Timeline
Manual Consolidate number of outstanding
by date
Reduce processing time and improve visibility of
recruitment status
Site Yokoten
Implementation Status:
Guide: 81% ~ 100%
8