Shop Floor Management

Shop floor management


Shop floor management is one of the most important ongoing activities performed in every organization. As stated by Kiyoshi Suzaki, author of The New Shop Floor Management; “ the shop floor is revered as the place where people ultimately add value to their society and strengthen its foundation.” Good shop floor management safeguards lean implementation and culture transformation. For this reason, W3 has acquired associates with extensive experience in shop floor management to assist organizations with their shop floor management needs.

The role of management today should be to develop and support the organization from the Gemba (shop floor) point-of-view. Through Shop floor management, organizations assemble the wisdom of their shop floor workers by practicing Glass Wall Management. This type of management helps organizations become more transparent, which enables employees to contribute maximum creativity as opposed to stifling their potential and creativity with Brick Wall Management. Furthermore, this type of management empowers individuals to self-manage their work and satisfy their customers by allowing each floor worker to manage their own mini-company. For shop floor management to be effective front-line supervisors must develop goals/metrics that are aligned with the overall Plant goals and share them both up and downstream. The result should be a narrowed communication gap between top management and the shop floor. By upgrading people’s skills, focusing on empowerment, and streamlining processes, the organization will realize concrete improvements and be able to adapt quickly in an ever changing market.

Shop Floor Management Objectives:

  • Create a steering team among members of the workgroups to help strive toward consistency across departments
  • Create a standard format for all Glass Walls used throughout the plant.
  • Establish appropriate Critical Few metrics specific and relevant to each model area
  • Decide necessary supporting documentation and format for each area
  • Provide training in roles / responsibilities for all key players; Team members, Team Leaders, Supervisors, Managers, Senior Managers
  • Establish a pattern, consistency, and quality of routine meetings:
    • Daily huddles between team members and leader
    • Weekly Report Out meetings between the team leader and management
  • Cultivate and reinforce the idea / thought process of
    • Daily Schedule Attainment
    • Daily striving / continuous improvement

Shop Floor Management Benefits:

  • Visual systems for Team members, Team leaders, Group leaders, and managers
  • Transparent data collection
  • Determines the key data to collect to better manage QDCSM
  • Establishes escalation process
  • Establishes a pattern of consistency and quality for routine meetings
  • Increased communication efficiency
  • Clarity of company oriented organization
  • Increased involvement of everybody
  • Better problem solving capabilities
  • Greater value for the end consumer