B. O. S.

1
B. O. S.

• Business Operating System

2
B.O.S. DEFINITION

• BOS is a practical and simple approach to
  coordinating key business and operating
  objectives with real projects and activities.
• BOS also provides a practical and simple approach
  to collectively use the tools we have discussed.

3
B. O. S. CHART

• Is a one page chart showing data trends
  identifying key factors, tracking projects and
  monitoring improvements.

4
WHY USE THE B. O. S. CHART TOOL?

• B. O. S. charting is a standard tool used to
  support visual control
• One page summary which facilitates management at
  a glance.
• Ensures real activities are occurring to improve
  the areas identified as important to the company
• Is an excellent communications tool
• to employees
• to management

5
BOS CHART FORMAT
6
BOS Key Measurable PPM - Steel Can Assembly Cell
Ref
Description
Resp.
End Date
1
Redesign finished goods packaging
AM
7/18/95
Procure new component parts
2
JK
6/30/96
containers
3
Improve weld in process weld
SL
7/24/95
monitoring system
4
Replace current controller on paint
GA
9/20/95
system
Ref
Description
Jan
Mar
May
Jul
Sept
Damaged
1
51
48
45
39
5
Assembly
2
20
20
18
20
19
Cracked Casing
3
Broken Weld
19
17
21
18
1
4
Paint Blister
14
19
18
10
14
7
BOS IMPLEMENTATION

• Identify key measureables
• Brainstorm
• Analyze data
• Pareto analysis works well
• List Improvement activities
• Fishbone diagrams
• Track improvement activities
• Unique measures

8
Fishbone Diagrams

• Lists the possible causes of a problem by
  considering the following areas
• Man
• Methods
• Materials
• Machines
• Environment

9
Fishbone Diagrams

• Continue to ask the Question Why until there is a
  consensus that the root cause has been uncovered

5 Why's
Problem
Why
Why
Why
Why
Why
Root Cause
10
Fishbone Diagram
Operator
Machine
Broken tool
Training
Calibration
l
Fatigued

Damaged Assembly

Out of spec
Ergonomics
Environment
Wrong
Material
Methods
11
Countermeasures

• Actions taken to ensure that root causes do not
  resurface at a later date.
• Examples of countermeasures are
• Error proofing
• Gauging and Fixturing
• Supplier Certification

12
Error Proofing

• Restricts the ability to incorrectly assemble a
  product
• Forms of error proofing in our products are
• Tabs
• Notches
• Unsymmetrical Features

13
Gauging and Fixturing

• Used when it is determined that an operation may
  introduce excessive variation to the final
  product
• Common examples are
• Weld Fixtures
• Final assembly gauges and fixtures
• Leak check fixtures

14
Supplier Certification

• How do we control the parts that we buy from
  outside sources?
• Part Number Certification
• Supplier Certification

15
Tracking Downtime

• Important tool for determining the best process
  for producing the product
• Areas to consider when analyzing downtime
• Process equipment
• Production Associates
• Material
• Methods
• Work Area

16
Process Equipment

• Downtime here may indicate that the equipment may
  need to be refurbished, updated or even replaced
  to be capable of producing an acceptable product

17
Production Associates

• Downtime in this area may indicate
• Training needs
• Lack of knowledge of acceptable product
• Incorrect line staffing

18
Material

• If downtime is related to material the following
  may be true
• The material may not be the best suited for the
  process
• The material quality needs to be improved

19
Methods

• Downtime in this area indicates excessive travel
  and or wasted motion as well as
• Equipment layout concerns
• Process bottlenecks

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Work Area

• Downtime may also be due to environmental
  problems
• Is it too hot or cold?
• Is there sufficient lighting?
• Is the work area safe?

21
Downtime

• Other methods of tracking downtime are used, they
  are
• Live production counts
• Andon alarms
• Downtime Clocks
• These are all excellent tools for at a glance
  management

22
Scrap Tracking

• Used in conjunction with other tools to determine
  the process problems
• Red Box Method of scrap tracking
• Identifies suspect product
• Records all defects
• Corrective action implemented and logged for
  future reference

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DEFECTIVE PART
CAN IT
BE REPAIRED
SET-UP
IN LESS THAN 1
/OR SUPERVISOR
CYCLE
DETERMINE CORRECTIVE
INTERIM ACTION IN ORDER TO
RESUME PRODUCTION
DOCUMENT ACTIONS
REPAIR PART
CONTINUE
NORMAL
PRODUCTION
SET-UP INFORMS
SET-UP /OR
INSPECTOR OF
SUPERVISOR
REASON FOR
DECIDE IF PART
SCRAP
REPAIRABLE
REPAIR PARTS
REFER TO WORK
INSTRUCTION
13.1.8, "SCRAP
SALVAGE"
CONTINUE NORMAL
PRODUCTION
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LETS REVIEW WHAT WHY

• B O S
• BUSINESS OPERATING SYSTEM
• B O S is a practical and simple approach to
  coordinating key business and operating
  objectives with real projects and activities

25
B O S IMPROVES COMMUNICATION

• Fosters management at a glance
• Insures communication of key goals to workers,
  management, visitors, everyone
• Allows operators to communicate activities and
  progress to management
• Facilitates visual control

26
BOS REQUIRES ACTION

• Proper use requires specific action to address
  key objectives
• Includes tracking progress of activities
• Demonstrates organizations commitment to
  improvement activities

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CONCLUSION

• These tools are simple to use
• They can be implemented in any area at Arvin
• B.O.S. charting visibly closes the loop from the
  measure and its cause to the actions being taken
  to improve

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Report Out Deliverables

• Present a B.O.S. Chart for Report Out Exercise 7.
  Use the standard 4 quadrant format.

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BOS Chart