Distribution of Production Line Responsibilities
The Process and Service Accountability system calls for support departments to anticipate and service routine needs on the production floor. Each department must track schedules and be ready to apply their contribution, unsolicited and as it is required.
Point–of–use responsibilities are assigned into support department zones. Each department has specific responsibilities on each production line within its zone.
Below are examples of generalized tasks assigned to support departments; specific tasks that are included in audit point databases.
The Engineering “Zone”: Certified processes, updated methods, procedures, visual aids, bills of materials and drawings.
The Maintenance “Zone”: Preventive maintenance procedures, adequate tools, and functioning equipment.
The Materials “Zone”: Correct part number and quantity of materials in bins, materials ready for next production order.
The Human Resource “Zone”: Correct number of operators, proper working environment.
The Production “Zone”: Demonstrated ability to carry out process steps and identify quality criteria, proper use of tools and equipment, knowledge of visual aids.
The Quality “Zone”: Evidence of monitoring and control actions of all elements in the company quality manual.
At the core of Process and Service Accountability is task execution. Drawings, manufacturing instructions and quality manuals are the sources of the tasks related to the company’s products. These define the correct materials, processes and procedures.
Daily audits confirm that routine tasks assigned to each department are executed as required. Tasks such as stock room cycle counting, spare parts inventory maintenance and updated employee personnel records are monitored along with production line responsibilities.
Aside the routine daily tasks there are non-routine needs such as a new process fixture from engineering, a training course from personnel or the remodeling of a conference room by maintenance. These activities are processed with service requisitions. Those needing the service define work and completion dates required. Requisitions are tracked and scored against their required completion dates.
The scores generated from task execution and service requisition completion are used as the basis of employee performance evaluation and compensation. The scores are applied to minimum, general and exceptional performance levels established by each company.
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