WPC Implementation Structure for Vithale Electrical

By: Conrad Sebego

31 MAY 2005

05/01/23 2

IMPROVING WORKPLACE PRACTICES ...

PRIMARY PURPOSETo facilitate and assist participating companies to transform the workplace through the implementation of practices/processes that lead to best operating practices (BOP) and world class manufacturing.APPROACHChange agents coach and train change facilitators and company team leaders in ‘best-in-class’ improvement practices.

Kaizen (continuous small step improvements) Kaikaku (breakthrough improvements e.g. plant layout, BPR,

etc)

Production Improvement StructureMANAGING DIRECTOR

PROCESS CHAMPION/COORDINATOR

TEAM LEADERS TEAM LEADERS TEAM LEADERSTEAM LEADERS

SPONSOR

MASTER COACH

COACHES

Company Value Chain

PRODUCTION SCHEDULING

PURCHASING AND STORES

PRODUCT QUALITY

CUTTING & PRINTING OF

WIRE

HARNESS ASSEMBLY

TARPLATE & MODULE

ASSEMBLY

TARPLATE WIRING

WIRING & ASSEMBLY OF

MODULE

MODULE INTEGRATION

The Teams

1xProduction Scheduling1xPurchasing & Stores1xProduct Quality2xWiring of modules

1xFinancial administration1xReception & creditors1x cleaner1xPurchasing & Stores

1xCut & print of wire6xWiring of modules1xHarness assembly1xTailplate & mod assy1xTaiplate wiring1xModule integration

1xCut & print of wire6xWiring of modules1xHarness assembly1xTailplate & mod assy1xTaiplate wiring1xModule integration

TEAM #1 TEAM #2 TEAM #3 TEAM #4

Plant Level Committee

2 x MANAGEMENT REPRESENTATIVES FROM TEAM 1 & 2+

2 X EMPLOYEE REPRESENTATIVES FROM TEAM 3 & 4+

MANAGING DIRECTOR

Role of the Plant Forum• Develop the Project Plan• Represent the natural teams• Implement the project• Monitor the project• Monitor the measures• Problem solve• Unpack issues• Support and develop the natural teams

Next Step• Facilitate a process to select team leaders• Identify meeting areas• Determine team names, establish team

mission and vision statements• Identify appropriate production and

performance improvement measures

Team 1• Ryan• Yusuf• Sipho• Sello• Peter

Team 2• Anna• Monica• Hasinna• Israel

Team 3• David• Florence• Llewellyn• Patricia• Magwaza, Michael Mabe, Bizo, Chris,

Stephen, Grace• Isaac

Team 4• Gaylynn• Esme• Jan• Macload, Michael Mlangeni, Albert,

Rachel, Jabu, Vusi• Ernest