Ford Advanced Lean Value Engineering Time Line
Ford Advanced Lean Value Engineering Time Line
Up to now……….
The Proposal
Supplier Lean Value Engineering Timeline
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
Supplier Lean Value Engineering Timeline
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
(CANDIDATES SELECTION) What? -Develop a consistent message to convey to the supplier at the Lean/ Value
Management Kick off meeting.
-Assess supplier candidate potential for the SALVE programme.
RESOURCES OUTPUT
Where? - Ford Basildon / Cologne / Valencia
Meeting Room List of potential candidates to
When? - 108 Weeks before Job1
TCM specialist [1] undertake the programme
Lean team rep [1]
How? - Face to face meeting, 3 hours long.
Purchasing [2]
STA [1]
Outcome: List of potential candidates to undertake the programme
Other considered:
Global sourcing devt. Eur [1]
Post event activities: Communicate to selected supplier candidates
Supplier Lean Value Engineering Timeline
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
RESOURCES OUTPUT
Outcome: -Go/No Go decision
Lean Team [2] Lean Level Indication
STA [1] Go/No Go decision
Site Management [2]
Post event activities: (Lean Team) – Feedback to Internal Ford Review Team
On site room
Supplier Lean Value Engineering Timeline
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
What? - Introduction by the supplier about their business and manufacturing strategies.
- Strategic Era Analysis (by Lean Team) to establish whether all the management
team are aligned and pulling in the same direction.
MANAGEMENT WORKSHOP
- Agreement on the direction and support requirements from the entire management team.
- Feedback on the results of the LAT and the priority areas indicated.
- Decision on the way forwards, involvement, commitment and outline timing plan.
RESOURCES OUTPUT
Where? - Supplier locality; preferably off-site.
Agreed vision for
-Supplier senior management manufacturing aligned to
When? - 92 Weeks before Job1
team [6] overall business needs
-Ford Lean Team [2] -Commitment from the senior
How? - 2-Day senior management workshop facilitated by the Lean Team.
-Suitable facilities local to management team
supplier site -Indication of the priorities
Outcome: - Understanding of the potential, commitment and opportunities.
-Workshop Materials (incl -Programme support team
- Site Management Buy-In
cost calc tools) -Overall timing plan
- Final decision point on whether to proceed with this supplier.
Post event activities: Supplier to commit to workshop series, selection of teams.
Supplier Lean Value Engineering Timeline
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
Why? To develop ability to recognise and eliminate waste in the manufacturing system.
Outcome: -Supplier team trained on Lean concepts of working smarter not harder
RESOURCES OUTPUT
-Established post event activities and timing
Lean Team Site team understanding of
Post event activities: Follow-up of suppliers activities by weekly report sent to Ford.
Lean Champion Waste Elimination, Labour
(Will be generic. Typically, communication, cascade training, proposal implementation,
Site Core Lean Team balancing and layout
monitoring and extrapolation to agreed areas).
Ancillary Team Members optimisation..
On site room & equipt Activity Plan to implement:
•Workshop Proposals
Post event activities agreed
Supplier Lean Value Engineering Timeline
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
How? Regular local meetings. Sharing of product development details, timing, capacity
LEAN / VM INTERFACE requirements and manufacturing strategy.
Outcome: Clear understanding of product and process optimisations as a going in point for
Advanced Lean workshop.
RESOURCES OUTPUT Cumulative Outcome from Lean programme: Site core team led by Lean Champion
that are knowledgeable and capable of creating a Lean Manufacturing System for the
VE site representative Alignment of Advanced Lean current and incoming production processes.
Lean Champion workshop focus with product
design, variance and volume Post event activities: Check programme timing, facility and equipment lead time for potential
planning. system.
Supplier Lean Value Engineering Timeline
1D 1D 1D 4D 2D 1D 5D 1D 5D 1D 5D 1D 5D JOB 1
Internal Lean Lean VM Supplier Site Management W/S SFW W/S SFW W/S SFW W/S SFW
Ford Review Quick Kick Off Lean diagnostic / VM workshop Prep Stabilisation Prep JIT Prep TPM Prep Advanced Lean
Assessment Meeting Event Workshop Workshop Workshop Workshop
(candidates selection)
(diagnostic period of XXX
weeks)
How? 5 day workshop to create specific Lean manufacturing system for the future product
RESOURCES OUTPUT line.
Lean Team [1 or 2] Lean Concept Outcome: Right First Time, Lowest Cost manufacturing plan.
Lean Champion [1]
Site Core Lean Team [4] Post event activities: Follow-up of suppliers activities by weekly report sent to Ford.
Ancillary Team Members [4] Flawless Launch (Will be specific. Typically, communication, cascade training, proposal implementation,
Commercial Rep [1] and monitoring).
Programme VE Rep [1]
On site room & equipt
Supplier Lean Value Engineering Timeline
Or
Enablers……
•A formal commitment from the Supplier
•A long term relationship between Ford and the
chosen suppliers
•A strong Supplier-Lean deployment link
•Empowered Teams
Supplier Lean Value Engineering Timeline
Next Steps……