Do you have so many metrics in your area, that it can be overwhelming and time-consuming trying to assess how things are performing each day? QDIP is a tool we recently discovered that has made this task much quicker, so you can get to the real issue, instead of feeling drowned in data overload, and not knowing where to begin!
QDIP is a daily process management tool to quickly provide a visual assessment of how a process is operating using 5 criteria: Safety, Quality, Delivery, Inventory, Productivity and Environment. With this tool, anyone can quickly assess the status of a process or cell in a matter of seconds. The diagrams allow you to track up to 31 working days (assume work is done every day of the month). Sheets are 8.5 x 11 inches in size with one criteria per sheet (see image graphic). File format is Microsoft Word (.DOCX).
If you use SQDC (Safety, Quality, Delivery, Cost) instead of QDIP, then you can use the plus sign (+) for safety, and we provide the letter C for cost or customer.
Many manufacturing facilities have a communications board or scorecard near the work area, but the problem is that there are too many charts to look at, and too much information to review. Management needs to be able to quickly look at one sheet per metric, and assess the performance in a matter of seconds, not minutes. These sheets address this gap by providing a simple green and red color coding.
At the end of the month, a manager can quickly assess when the problems occurred, and determine what the emphasis should be in the upcoming month to resolve these issues. If the entire diagram for a given criteria is green, then the key metric should be modified to make it more of a challenge. If the entire diagram is red, then either the metric is too difficult, or there are additional resources or prioritization that is needed to help address those issues.
How do I implement QDIP/SQDC in my area?
Step 1 – Define Key Metrics for each criteria
Example Metrics for each Criteria
|Safety||Quality||Delivery||Customer / Cost||Inventory||Productivity||Environment|
|– No missed days
– No injuries
|– Less than 5 defects per day
– DPMO less than 50
– Test Yield greater than 95%
|– 100% on-time to customers, schedule, next process, etc
– Complete 10 units per day
|– No escape notifications
– No defects at installation
– No warranty claims in first 3 months
|– WIP less than 10 units
– No more than 3 pieces at each station
– WIP less than $10,000
|– $/hr greater than $150
– Less than 10 minutes of downtime
– Team met daily takt time goals
|– All equipment shut off at end of shift
– No recyclables in trash
– 100% Hazardous waste adherence
Step 2 – Display new QDIP/SQDC diagrams at beginning of each month
It is recommended that you place them in this order, in a location for everyone (employees and management) to view. You can either laminate each sheet and reuse each month (clean off previous month), or print out a new sheet each month, so you can retain the history
Step 3 – After each production day, color the day on each diagram with GREEN (met goal) or RED (did not meet goal)
After each day, the manager or leader can walk around and look at the most recent day marked on the sheet, to determine whether each metric was achieved. They should only spend time discussing the red items on the sheets, not the green. This should simplify the time spent at each area, and reduce the overall management review time.
Example: After Day 5
Here are the results from the first 5 days of the month:
– Safety did not meet their metrics on Day 2
– Quality and Delivery did not meet their metrics on Day 4
– Inventory did not meet their metrics on Day 4 and 5
– Productivity did not meet their metrics on Day 1 and 2
– Environment did not meet their metrics on Day 1
Example: After Day 10
After day 10, Quality has fallen short 2 days, Delivery 5 days, Inventory 3 days, Productivity 4 days, and Environment 3 days. On the 10th day, only Delivery has failed to meet its metrics.
Example: After Day 15
Example: After Day 31
At the end of the month, a manager or leader can quickly assess how often problems occurred, and what the emphasis should be in the upcoming month to resolve these issues. If the entire diagram for a given criteria is green, then the key metric should be modified to make it more of a challenge. If the entire diagram is red, then either the metric is too difficult, or there are additional resources or prioritization that is needed to help address those issues.
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