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1.1ProcessorientationCommentsNoContents01234StandardsStandardsStandardsStandardsStandardsValueStreamPlanningValuestreammapping&designexistsforonepilotarea.BasicKnow-Howexists.ValueStreamsarereviewedregularly.Valuestreammapping&designexistsforatleastasecondvaluestream.RolloutplanforallrelevantBoschvaluestreamsexists.SystemKnow-Howexists.AleanManagerisappointedtodrivetheleanprinciples.ValueStreamsarereviewedregularly.ALeanproductionsystemexists.Valuestreammapping&designisrolledoutthroughoutthewholeplant.AleanManagerisappointed.ValueStreamsarereviewedregularlybasedonthecompanytargets.ALeanproductionsystemexists.Valuestreammapping&designisrolledoutthroughoutthewholeplant.AleanManagerisappointed.ValueStreamsarereviewedregularybasedonthecompanytargets.SupplieriscapableandwillingtotrainothersuppliersontheprinciplesofleanproductionVSMShiptoLineShiptoSupermarketSupplierisdeliveringpartsonaquality-levelthatrequiresincominginspectionSupplierisdeliveringparts/materialonaqualitylevel,thatnoincominginspectionisrequiredatBosch.(shiptostock,shiptosupermarket,shiptoline)Supplierisdeliveringparts/materialonaqualitylevel,thatnoincominginspectionisrequiredatBosch.Materialisdelivereddirectlytotheline.(shiptosupermarket,shiptoline)Supplierisdeliveringparts/materialonaqualitylevel,thatnoincominginspectionisrequiredatsuppliers.AllA-partsaredelivereddirectlytotheline(shiptosupermarket,shiptoline-onlyonestocklocationexists).Suppl.InterfaceFloworientedLayoutFirststepstowardsimprovingmaterial/productionflowhavebeensuccessful,howeverthereisnoprojectplanstomovepastthispoint.Theactualsituationisidentifiedinpilotarea:TransportationpathsaremeasuredwithSpaghettidiagram,Processrelationswithbubble-diagram.Avaluestreamanalysisanddesign(VSA/VSD)andanoptimizallayout-concepthasbeencarriedoutinpilotarea.Targetconditionandmeasures(i.e.pullsystems)areidentifiedandimplementedtoimprovethematerial/productionflow.Avaluestreamanalysisanddesign(VSA/VSD)andoptimizallayout-concepthasbeenappliedtoallRB-products.Targetconditionandmeasures(i.e.pullsystem)areidentifiedtoimprovethematerial/productionflow.ChangesmadeinpilotareaaresuccessfulandtoolshavebeenputinplacetoassuresustainabilityAvaluestreamanalysisanddesign(VSA/VSD)andoptimizallayout-concepthasbeenappliedtotheentireproductionarea.Targetconditionandmeasures(i.e.pullsystems)areidentifiedtoimprovethematerial/productionflow.ChangesmadeinRBProductareasaresuccessfulandtoolshavebeenputinplacetoassuresustainabilityFOLLeanLineDesignLLDisappliedtoBoschpilotline.LLD-modulessuchasstandardizedwork,POU-provider,pokayokeareknownbyLeanmanager.LLDisappliedtoallBoschrelevantproductlines.LLD-modulessuchas:standardizedwork,POU-provider,pokayokearewellestablishedatshopfloormanagementlevel.Production/assemblylinesareflexibletocovervariouscustomerdemandsbyno.ofoperators.LLDisappliedtoallrelevantproductlines.LLD-modulessuchasstandardizedwork,POU-provider,pokayokearewellestablishedatshopfloormanagementlevel.Production/assemblylinesareflexibletocovervariouscustomerdemandsbyno.ofoperators.LLDGHCMaturitylevelofconceptSDLeanMaturityAssessmentV2.0Level1.1ProcessorientationAuthor:CP/ASD-EU,Version2.0released01.08.2012file:Lean_Maturity_Assessment.xlsx1.2PerfectQualityCommentsNoContents01234StandardsStandardsStandardsStandardsStandardsTPM-Eliminationofproblems-Maintenance-OrganisationTPM-Pillar1:-OEEMeasurementinstalledandrunning-TPMplansforautonomousandplannedmaintenanceofMAEareinplaceandinuse.-Directassociatesdocleaningandservicesundersupervisionandthereformanpowerandtimewindowsarereserved.TPMPillar2:-Structuredprocesstoeliminatemainprobllemsforlossesexists(i.e.Point-CIP)andistransparent-Plannedmaintenanceissynchronizedbetweenallrelevantareasandthelevelingresp.productionpattern-Directassociatesdocleaningandservicesindependentaccordingtomaintenanceinstruction.TPMstrategyandappropriatestructureisinstalled.TPMPillar3:-Strategytoidentifyunknownlossesinthehourlyrecordsisavailable(i.e.ShopFloorManagementCycle)-Directassociateddominormaintenanceworkundersupervision-TPMplans(autonomousandplanned)aredevelopedinastructuredway(i.e.extensionofperiodbyanalysisofexchangedspareparts)TPMPillar4:-Meantimebetweenfailure(MTBF)istrackedatbiottleneck-processesofplannedmaintenancearecontinouslydevelopedfurtherbasedonstandardizedwork.-Continousmonitoringofmachinesbydirectassociatesandplannedreactionincaseofdeviation.-TPMstrategyandappropriatestructureiscontinouslydeveloped.TPM5STherearenostandardsevidentformaintainingacleanandorganizedshopfloor5SStandardsexistforthepilotlineandareconfirmedonaregularbasis.Aplanisinplacetoimprovetheoverallorganizationofthepilotarea.5SStandardsexistforthepilotline,commonareasandthewarehouseandareconfirmedonaregularbasis.Aplanisinplacetodrivecontinuousimprovementintheorganizationoftheseareas.Theseareasarealwayscustomerready.Tools,guagesandsuppliesarewhereyouneedthem,whenyouneedthemanvisuallyinperfectorder.5SStandardsexistforallBoschrelevantmanufactoringareas.Continuousimprovementplansexisttoimprovetheoragnizationofthoseworkare