Poll – DVIRC Lean Assessment

The Lean Six Sigma Assessment
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First name

Last name

Company

Email

Phone Number

EMPLOYEES

How many employees work at your site?

Over 150

101 - 150

61 - 100

31 - 60

11 - 30

1-10

1

DELIVERY

What is your on time delivery rate?

91% - 100%

81% - 90%

71% - 80%

51% - 70%

Less Than 50%

Not Measured

2

FIRST PASS YIELD

What is your first pass yield from your production line?

91 - 100%

81-90%

71 - 80%

51 - 70%

Less than 50%

Not measured

3

CHANGE OVERS

How long are your change overs between jobs?

Less than 10 minutes

10-30 minutes

31-60 minutes

61-90 minutes

91-120 minutes

Over 120 minutes

4

CONTINUOUS IMPROVEMENT TRAINING

How much continuous improvement training have you completed?

We have been trained and have a formalized process to continue training

We Have Had Extensive Training

Several Training Classes Within The Last 5 Years

Some People Have Basic Training

Very Little More Than 5 Years Ago

None

5

WIP

How much WIP do you have in your processes?

Almost None

Just A Few Hours Worth

Less Than One Day Worth

Less Than One Week's Worth

More Than A Week's Worth

More Than Two Week's Worth

6

HIGH PERFORMANCE CONTINUOUS IMPROVEMENT TEAMS

What level of competence have your leaders and managers demonstrated in developing and supporting high performance CI teams?

We Have Been Trained And Have A Formalized Process To Continue Training

We Have Had Extensive Training

Several Training Classes Within The Last 5 Years

Some People Have Basic training

Very Little Or More Than 5 Years Ago

No Training

7

SCRAP

How much scrap do you generate?

0% - 2%

3% - 5%

5% - 10%

11% - 20%

21% and Up

Not Measured

8

SHOP FLOOR

How easy is it to recognize if things are missing or out of place on your shop floor?

We Have An Active 5S Program And We Review It Annually

We Have An Active 5S Program

Most Things Are Where They Should Be

Some Things Have A Place

There Is Much Room For Improvement

Not Easy

9

KPIs

How does production know if they are having a good day? Do you have KPIs?

We Make Every Decision Based Off Data

We Have A Few Key Charts That We Live By

We Collect Lots Of Data And We Sometimes Refer To It

We Collect Lots Of Data But We Rarely Look At It

A Few Charts Are Created But Rarely Reviewed

Not Measured

10

PLANT LAYOUT

How much do your employees walk to get materials or move product?

We Have All The Materials and Equipment That Our Employees Need Right At Their Station

Our Work Cells Are Pretty Well Organized WIth Little Employee Movement

There Is Some Movement Of Employees

They Have To Go A Significant Distance To Get What They Need

Our Employees Are Often Searching For What They Need

Never Checked

11

ENGAGEMENT

What percentage of your employees would you describe as actively engaged?

All

Most

More Than Half

About Half

Very Few

None

12

CHANGE

How receptive are the people to change?

Welcomes and Receptive To Change

No Resistance

Little Resistance

Moderate Resistance

A Lot Of Resistance

Almost Impossible To Implement Change

13

FRONT OFFICE

Has the front end of the business been exposed to CI?

Yes We Are All Trained And Practice CI On A Regular Basis

Many Have Been Trained And We Use The Skills Often

Some Have Been Trained And We Use It Periodically

Training Has Been Scheduled

We Have Explored Training

None Have Been Trained And We Don't Use Those Skills In The Front Office

14

EQUIPMENT

How often are your machines down during production?

Uptime Over 97%

Uptime Between 91% and 97%

Uptime Between 81% and 90%

Uptime Between 71% and 80%

Uptime Less Than 70%

Uptime Not Measured

15

CONTROL

Do you fully use control charts on your shop floor to manage production?

We Actively Use Control Charts and Review Data Integrity

We Have A Run Chart With Control Limits And Use Some Data To Make Decisions

We Have Run Charts and have Started Looking At Control Limits and Data

We Have A Run Chart But No Control Limits and Data Is Not Reviewed

We Are In The Early Stages Of Identifying Control Charts And Control Limits

We Don't Use Control Charts

16

IMPLEMENTATION OF CONTINUOUS IMPROVEMENT

How is continuous improvement implemented in your organization?

Highly Effective Daily Management With Significant Employee Involvement

Formal CI Program In Place With The Majority Of Employee Participation

Formal CI Program In Place With Moderate Employee Participation

Formal CI Program In Place Led By Management

CI Activities Extremely Reactive

None

17

CONCERNS

Are there repetitive concerns with quality, productivity, safety, ergonomics, human error?

No Issues

Some Concerns

Frequent Concerns

Monthly Concerns

Weekly Concerns

Daily Concerns

18