(i) Scenario delimitation and evaluation of the scenario |
Plant managers (6 coordinators and 5 managers) |
Assessment questionnaire of compliance between scenario and CSF for implementing the help chain structure |
(ii) Identification and classification of abnormalities. |
2 process engineering coordinators and 2 process analysts |
Abnormality registering system (via SAP ERP) |
(iii) Identification of the visual device types and contents |
3 production and maintenance managers from the paper and cardboard department, 2 process engineering coordinators, 2 process engineering analysts, 4 graphic technicians (1 per machine), and 1 external consultant (A3 process specialist) |
Printing company proprietary guidelines for implementing the lean philosophy in its worldwide subsidiaries; production note forms, quality defects, and downtime; planned production calculation spreadsheet; quality assessment worksheet; internal classification of occupational safety risk levels; and the literature on the problem-solving process, A3, andons, and visual management |
(iv) Identification of agents involved in the help chain |
3 production and maintenance managers from the paper and cardboard department, 2 process engineering coordinators, 1 maintenance coordinator, and 2 process analysts |
Hierarchical structures of the printing and maintenance areas; placement of employees in work shifts; matrices of functional competences and professional history (length of the experience in the function) |
(v) Defining the help chain operation logic |
3 production and maintenance managers from the paper and cardboard department, 2 process engineering coordinators, 1 maintenance coordinator, 2 process analysts, and 1 maintenance analyst |
Documents and products from previous steps; historical records of break and fail reports (BFR); mapping of potential abnormalities; previous time and movement studies of the Maintenance department; and the literature on routine management |
(vi) Training the agents involved |
3 production and maintenance managers from the paper and cardboard department, 10 process analysts, and operators from all the printing production sectors |
All the documents/products resulting from the previous steps and literature on help chain, A3 process, routine management, and visual management |
(vii) Application and evaluation of results |
3 production and maintenance managers from the paper and cardboard department, 10 process analysts, and operators from all the printing production sectors. |
Structures and routines created for the help chain, resulting from the previous steps; production system (OEE and scrap) metrics pre- and post-implementation; and unstructured interviews. |