A3 reports
- 1. A3 Reports
- 2. Aims & Objectives Target Audience :Anyone who has to write a report or proposal Purpose of Module :To confirm understanding and benefits of A3 report writing to how to create one. Aims & Objectives : • To confirm understanding of how to clarify thinking in a concise way • To define a standard format for reports • To guide in the various steps in the creation of a report • To demonstrate the ability to create an A3
- 3. Course Agenda •Define a standard format for reports •Guide in the various steps in the creation of a report • To demonstrate the ability to create an A3
- 4. What is an A3 Report A process used to document and report solutions to problems established within any area of the organisation. This differs from other types of report in the way that all information is disclosed on an A3 sheet. Data being: •Aim •Objectives •Methodology •Result •Post result analysis •Learning points
- 5. Why A3 Report A3 Reports offer a simple and structured approach to reporting solutions to problems. A3 Reports are particularly effective in demonstrating to third parties the development stages of a fault, in reaching a solution. A3 Reports reveal the actions taken, or to be taken, in eradicating faults. A3 Reports reflect the benefits of implementing a particular methods to a problem, with the provision of justification. Essentially, A3 Reports leads to the identification & elimination of waste, in order to control processes.
- 6. 80 / 20 Rule When writing the report remember the 80/20 rule! •What •when Summary 20% •where •why •who •how Detail 5 w’s 1 h 80% Proposal
- 7. Make it Easy to Read! Summary If it’s difficult to read I’m not going to Summary read it and you will not get Summary what you want! Detail 5 w’s 1 h Proposal
- 8. Show the Status if Report on Progress status -on plan Summary -away from plan with recovery action in place x -away from plan, no recovery in place Detail 5 w’s 1 h Proposal
- 9. A3 Reports - Example A3 Report Title: Area or fault that A3 report is being implemented for. REPORT NUMBER: A number must be assigned to report for tracaebility purposes. AIM: Simple & Concise statement reflecting targets or problem RESULT: Results obtained from pursuing described description. methodology, in satisfying aims and objectives. OBJECTIVES: Listing of all objectives necessary to achieve aims (bullet points). METHOD: Step-by-step description of method to be employed in satisfying aims and objectives. POST RESULT ANALYSIS: Suggested changes in LEARNING POINTS: Conclusion to an A3 Report. Was methodology, in order to improve results obtained. aims and objectives satisfied? Any unexpected findings observed?
- 10. How? Decide and construct your story Must satisfy your reader’s needs Visualise you’re A-3 *Does it tell a story? *Is it brief, concise? Decide type of A-3 Provide information to Support your story Determine your goal. What’s the purpose? Did we reach a conclusion? What’s the recommendation? Did we satisfy our goal? Analyze your information Charts, graphs
- 11. A3 Reports - Benefits •Helps define a standard for all to use. •Provides a clear and concise method of reporting information. •Method of operation is visible and accessible to all. •Can promote communication, and team working. •Leads to reduction of waste. •A continuous improvement activity. •Creates efficient working environment.
- 12. A3 Reports - Example PROPOSAL STORY TO: (replace this heading with your title) DATE: FROM: PROPOSAL, Cont’d THEME INTRODUCTION PLAN WHAT WHO WHEN _____________________________________________________________________ __________ PROPOSAL _____________________________________________________________________ __________ _____________________________________________________________________ __________ UNRESOLVED ISSUES
- 13. A3 Reports - Example PROBLEM SOLVING REPORT STORY TO: (replace this heading with your title) DATE: FROM: THEME COUNTERMEASURES PROBLEM SITUATION IMPLEMENTATION WHAT WHO WHEN ______________________________________________________________________ _________ ______________________________________________________________________ TARGET/ GOAL _________ ______________________________________________________________________ _________ ______________________________________________________________________ _________ CAUSE ANALYSIS FOLLOW-UP
- 14. A3 Reports - Example STATUS REPORT STORY (replace this heading with your title) TO: DATE: FROM: THEME BACKGROUND TOTAL EFFECT OBJECTIVES UNRESOLVED PROBLEMS/ FUTURE ACTIONS IMPLEMENTATION
- 15. A3 Reports - Example INTRODUCTION TO: Name: DATE: FROM: Plant: PLANT LEARNINGS (Cont’d) PURPOSE OF VISIT PLANT LEARNINGS IMPLEMENTATION PLAN WHAT WHO WHEN 11
- 16. A3 Reports - When to Use Them Anytime you wish to clearly tell a story, especially when You wish to simplify or clarify a complicated issue 12
- 17. A3 reports - Why? BECAUSE AN A-3 REPORT encourages…. •Logical Thinking – What/How to accomplish •Decision-Making – All facts on one page •Provides Standardised Method of Communication – is easy for to recognize and read •Forces Addressing of All Issues – any steps/facts left out? •Focuses Problem–Solving Activities – 5 Whys •Eliminates Waste – New methods help you think about waste and how it can be eliminated •Forces You to Ask: Why do this? Does it make sense? Will it improve the current process? Will it solve a problem?
- 18. A3 Reports - Why? A3 Reports - Why REDUCTION IN VARIATION -Standardised Format QUICK SET- UP -Standardised Format LEAD TIME -Promotes quicker decision making REDUCTION -Concise, clear communication ERROR -Easier to spot defects PROOFING -Improves decision making SMALL LOT STRATEGY -Reduces multi-page reports to one VISUAL -Standardised Format CONTROLS PEOPLE -A standardised approach to business communication used to develop people •Eliminates waste •Lowers costs •Improves profits
- 19. A3 Reports - Summary •Plan time to grasp the ENTIRE situation •Decide what kind of story you need to tell •Relate the story to top company values, philosophies •Make your story flow in a logical sequence •Save words – use graphs and visuals •Make every word count
- 20. Example Date Issue Sign G.M/ MMT. Key Stakeholders. H.O.L. Ch.Eng.. Origin. TU Module: 1. Purpose of this module / element. 2.Benefits Definition: Helicopter view: 3. Proposal Step by step Highlight on Simulations route map Experts to examples route map summary Standard Glossary exercises Detailed Training Memory courses Worked joggers contact studies formas guides Exec. Case Elements Detailed view: 4. Potential issues and countermeasures 5. Reference documents:
- 21. Case Study
- 22. Case Study Quick Changeover (QCO) Purpose Bring a batch production process as close as possible to a flow production process! Increase the flexibility of the process! Explanation/ How to proceed 6 Draw current state 1 What is QCO? 5 Implementation Steps c/o process steps Purpose: Display the actual situation in a standar- recorded 1. Select a production team and train the people in the A standardised method for a production work group to analyse and dised way to to get a common understanding new methods and their roles and resposibilities. significantly reduce set-up time. of the problems or potential improvements. 2. Select the target area • Select the target area Change over time is the time between the last good part of one 3. Document the current c/o Method ( Video, Spaghetti • Display the activities production run to the first good part of the Next Production run. – Chart, Step Chart, Standardised Work Sheet ) • Standardise the steps and the work content 4. Develop the Future State. An important influence on the QCO activities has the required 5. Implement the Suggestions ( Activity Plan, process capacity to satisfy the customer demand in planned Standardise the new situation, train the people ) Standard Work Sheet (SWS) production time (Customer Takt ) Standard Work Sheet (SWS) 6. Monitor the success Leadtime / lot / part No. 7. Identify long term equipment modifications Create a SWS for the Create a SWS for the current state to show current state to show 100 parts A c/o 100 parts B c/o workplace and and workplace and and 4 Quick Change Over Method c/o process. QCO activities c/o process. 8 Standardise & Document Draw current state 50 parts A Qc/o 50 parts B Qc/o 50 parts A Qc/o 50 parts B Qc/o 7 Validate Procedure/Verify Results c/o Matrix: • Show the waste (walking, Result 6 Implement the Plan 1. To decide the target (i.e. Look at the red (difficult) c/o first) transport, tooling storage ! Same volume produced etc.) 5 Streamline Internal/External Activities 2. Useful aid for production control in ! Leadtime/product cut in half. Products can be pulled by next process deciding the production sequence for much earlier 4 Locate Parallel Activities different products 3 Shift Internal Activities to External 7 Draw future state 2 Objectives 2 Separate Internal and External Activities Bring a batch production process as close possible to Design future c/o process : a flow production process 1 Document Current Changeover Elements Traditionally Future CHANGE OVER TIME 1 Document Current C/O Elements ! Big lot sizes, avoid c/o ! Small lot sizes, frequent c/o RU RUN Draw future state ! C/o not done by operator but ! C/o done by operator NA All Changeover Elements B • Waste removed (less by maintenance people ! Standards for all c/o processes 8 Considerations for future equipment planning walking, transport, tooling ! No c/o planning ! Produce product on demand 2 Separate Internal / External Activities 50% Reduction prepared in advance etc.) ! High inventory/long lead ! Lower manufacturing costs RU Internal RU NB EXT times ! During the planning phase for new equipment provide NA . for quick and simple c/o. 3 Opportunities for improvement ! Use o-point systems (Nullpunkt-Systeme) 3 Shift Internal Activities to External Additional 25% Reduction ! Use common fixtures 4 Locate Parallel Activities 80% Workplace RU Organization & 10% Equipment ! Avoid threads in favor of quick release mechanisms NA Internal RUN B EXT. Record new c/o Management times to C/o Time 5 Streamline Internal/External Activities Additional 15% Reduction visualise and RU RU sustain NA NB EXT. improvements Internal 6 Implement the Plan Current Test 7 Validate Procedure/Verify Results8 Document New Procedure on a SWS State Date 5% Tooling 5% Product Design Properties Hints for implementation Relation to other – elements: * QCO integrates the c/o into the production responsibility • QCO activities focus firstly on bottlenecks (determined by e.g. VSM on a large scale • Standardised Work and by the c/o matrix on a smale scale) • SPC Service Departments are involved by supporting the production in • 5S – Visual Management reaching • All shifts have to be involved into the activities. • Logistics their production targets. • TPM • QCO has a significant impact on the traditional roles and responsibilities of Overriding Metrics is the Production Performance. • VSD production and service. Issues have to be solved before starting the module. • Performance Measurables