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How to develop an efficient and safe production workshop with the Shopfloor Management System?

What is the Shopfloor Management System?
The Three Pillars of the Shopfloor Management System Approach: the 3G
The 6 Main Objectives of the Shopfloor Management System
5 Keys to a Successful Implementation of the Shopfloor Management System

As we know, the production workshop is an essential component of any manufacturing company. It includes activities such as production, assembly, and manufacturing.
To have a high-performing production unit, companies are increasingly looking to integrate the principles of Industry 4.0.
To ensure optimal coordination of all these operations, I invite you to explore with me Shopfloor Management (SFM)

What is the Shopfloor Management System?

Shopfloor Management is a management method specific to production workshops and factories. It enables a production workshop to have a clear, secure, and stable work process, focused on precise objectives, thanks to visual management.
According to Kiyoshi Suzaki, author of “The New Shop Floor Management”, this method encompasses all activities related to the factory: inventory management, equipment management, operations, manufacturing, and product processing.
In this article, we will explore the pillars of the Shopfloor Management System approach, the essential components, and finally, the keys to a successful implementation.

The Three Pillars of the Shopfloor Management System Approach: the 3G

It’s important to note that Shopfloor Management is based on three pillars (which are also found in lean principles):

Gemba

Gemba means “the place where the action happens”; it refers to the workshop, where value creation and waste identification meet. Managers and leaders must regularly go to the shop floor to observe and understand production processes in real-time. I particularly like Taiichi Ohno’s quote (the father of the Toyota Production System): “Without gemba, there is no kaizen” (continuous improvement).

Genchi Genbutsu

Genchi Genbutsu is a concept closely related to Gemba. It means “go to the source to verify that you have the right information to make the right decision.” This is a broader approach than Gemba, encouraging managers not only to observe but also to actively participate and engage in the problem-solving process.

Genjitsu

Genjitsu is based on the use of precise data for in-depth analysis. It involves using factual information as a compass to make informed decisions. A classic example is the use of visual dashboards to monitor key performance indicators (KPIs) and facilitate decision-making based on real data.

The 6 Main Objectives of the Shopfloor Management System

Now that the pillars have been established, let’s look at some key objectives of the Shopfloor Management System that you should keep in mind.

1. Identification and Reduction of Problems

If I had to choose just one objective, it would be this one. The Shopfloor Management aims to quickly detect and solve problems within the workshop. The use of visual tools, such as performance tracking boards and key performance indicators (KPIs), makes problems immediately visible, always with the goal of a quick and effective response.

Some tools we recommend: Visual Dashboards, Boards, Pareto Charts (to identify the main causes of problems).

2. Optimization of Flows and Processes

As Jack Welch, former CEO of General Electric, said, “Speed is everything. It’s the essential ingredient for competitiveness.” Shopfloor Management should also aim to improve production processes to increase efficiency. This includes streamlining workflows, eliminating waste, and improving resource utilization.

The use of Kanban (a visual stock management system that helps optimize flow) is often worth considering.

3. Improving Communication

Communication is essential on the shop floor. The use of connected tools and visual and verbal communication methods ensures that information flows easily and quickly across different levels of the organization.

We recommend daily meetings, Andon boards (which display real-time production status and alert on issues requiring intervention), and the famous Gemba Walks.

4. Creating a High-Performance and Clean Workspace

Shopfloor Management promotes the creation of an organized, clean, and efficient working environment. The 5S methodology is often used to maintain order and cleanliness in the workshop.

Visual boards to track maintenance activities and corrective actions are also appreciated.

5. Increase in Production Efficiency

One of the core objectives of Shopfloor Management is to maximize production eficiency through continuous improvement. By involving employees in Kaizen initiatives and encouraging improvement suggestions, processes will become more efficient. Integrating the Plan-Do-Check-Act (PDCA) method to solve encountered problems is recommended.

6. Team Autonomy

Allow me to quote the great Steve Jobs: “Great things in business are never done by one person; they’re done by a team of people.”

The goal is to make teams more autonomous and responsible for their performance. How? By providing employees with the necessary tools and training, and involving them in operational decisions.

5 Keys to a Successful Implementation of the Shopfloor Management System

Now that we’ve covered the objectives, let’s explore 5 keys to successfully implementing the Shopfloor Management System (SFM).

Structured Communication and Meetings (Cascade Management)

It’s essential to establish a clear “cascade” of communication throughout the organization. The goal is to ensure that decisions are made at the appropriate level to create an effective organization. Leverage field experience to define this structure.

Commitment to Solving Problems Permanently

Sustainable problem-solving is a crucial element. To achieve this, it’s important to involve everyone in identifying and resolving issues. At Amazon, employees are encouraged to propose solutions to problems they encounter on a daily basis.

Direct Support from Leadership

Leadership must actively encourage and support such initiatives to enable overall improvement of the workshop.

Use of Traditional & Digital Tools

Take advantage of this opportunity to enhance operations by introducing digital tools (e.g., touchscreens…).

Emphasis on Visual Tools

Shopfloor Management heavily relies on visual tools such as machine tracking boards, SQCDP boards, Kanban, and PDCA boards, so don’t hesitate to use them!

In conclusion, Shopfloor Management, through the integration of visual and digital management, is a powerful lever for optimizing production operations, improving communication, and fostering a culture of continuous improvement within the workshop.

Lean Corner