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IEM 2903 MANUFACTURING AND SERVICE SYSTEMS AND TOOLS I

Fall 2018

Project #2 (75 points) Naming syntax: Last name_Project#2.doc

(use name of team leader – submit one per team) Process Analysis/Continuous Improvement

75 points – Team Report – Due: Sunday, December 2nd, 2018 at 11:59 pm Submit to the dropbox on Brightspace

Team formation: 1. You may work in groups of up to 3 people 2. You may form your own teams

The objectives of this exercise are:

1. Obtain experience in applying process improvement and process mapping techniques 2. Introduce students to real-world problems 3. Develop effective team skills

Deliverables:

1. Select a process for analysis and improvement. This can be one that you are familiar with or one that you are interested in learning more about. Be sure to include why this process is interesting or important to your group and other “customers”.

2. Develop the appropriate “as-is” flowchart (this should include a flowchart that has a minimum of 15 tasks). Describe how your group developed the chart.

3. Who are the key stakeholders in your process? What are some key issues to address in order to get the employees/participants buy-in for improving the process? Who are the customers of this process?

4. Identify one area for process improvement for your problem. What data could you collect to improve the process? Identify 3 performance metrics that are pertinent/meaningful.

5. Collect the pertinent data for one of the performance metrics outlined in #4. Use the data analysis/quality tools presented in class to identify and justify your proposed changes.

6. Based upon our discussions in class for process improvement, identify and document (including a flowchart(s)) your recommended improved process. This is very open-ended on purpose – the point is for the group to figure out what applies in your situation and document those items.

7. What is the bottom line of your analysis? Include your recommendations for next steps. 8. Your recommendation/analysis should be in the form of a written report (see below).

Team document: A maximum six page document, single-spaced, 12 point Times New Roman font using the sections as

described below. Insert page numbers on the document. Leave one space between headings and text. Use normal margins of one (1) inch top, bottom, and both sides. The audience for your report will be Dr. Glenn. Only the first six pages of your report will be read. If you go over the six page limit, even by one line, you will lose professionalism points, one point for each line over the limit, five points maximum. Supporting analysis, data collection results, interview notes, tables, etc., may be placed in appendices. These will not be counted in the six pages.

Simple Rules for good report writing (Thanks to Dr. Gary Foutch and Jennifer Block for many of these rules) • Write short, direct sentences. • Sentences should average 10 to 15 words each. • Maximum sentence length is 25 words. • Maximum paragraph length is 5-6 sentences • Watch for ‘rhetorical’ statements such as ‘It is very important to study processes.’ While true, these statements

add no informational value. • Make every sentence count. Use tables and figures to communicate data and complicated information. • Avoid repetition of words. Do not use the same word (except for articles) twice in a sentence, and try not to

repeat any expression in the same paragraph. Never start a sentence with the same word as the preceding. • Use superlatives (very, great, etc.) sparingly or not at all. • Watch out for the TERRIBLE T's (the, that, there, and then). Do not start more than ½ of the sentences with

them. • Watch out for subject-verb agreement. • Watch out for run-on sentences. • Use past tense and third-person, except in the Introduction and the Conclusions. In those sections the first

person is allowable. • Be specific and quantitative. Throughout the entire report, especially in the introduction and conclusion, be

specific and give values. An Airbus A380 isn’t big. It is 240 ft long with a wingspan of 262 ft. Engineers need quantitative information, not qualitative. Always attach units to numbers when applicable. Don't assume readers will "fill in the blanks". You need to tell them everything.

Report Contents Title Page

List the title of your project, the team members and the date Executive Summary

One page or less. The executive summary is an explanation of the project that is written for someone without technical experience that does not have the time to wade through the pages of technical details. Here in one good reference for what is expected from an executive summary:

http://www.ivanwalsh.com/business-development-strategic-planning-tips/warren-buffett-on-better- business-writing/4443/

Table of Contents

The title page, executive summary and table of contents are NOT counted in the six pages

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1.0 Introduction

The introduction is a single paragraph that provides an overview of the report, and tells the reader what to expect. For example: This report contains an analysis for……. First, the methodology will be described, then……….. Finally, recommendations are made.

2.0 Methodology

Describe your methodology. This is where you will describe how you approached the analysis of the process. Use your flowcharts to help communicate your understanding of the important activities.

3.0 Results

Summarize the results. What did you discover? Better reports will communicate these answers effectively (i.e., not just repeating the question and stating the answer - rather, tell the story). Calculations and supporting materials can be placed in the appendices.

4.0 Recommendations and Conclusions

What are your recommendations based upon your process analysis? Include what actions should be taken and any other recommendations you have.

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The List of References and Appendices are not counted in the four pages. List of References (if necessary) Appendices