aLF English - E01

aLF (adidas Lean Fulfillment)

General guideline on how to apply each level when making the evaluation

Level 0: The component is not in place at all or there are major inconsistencies in implementation --- score 0

Level 1: The component is in place but there are minor inconsistencies in implementation --- score 1.0

Level 2: The component is fully in place and effectively implemented --- score 2.0 Level 3: The component is fully in place, effectively implemented and exhibits improvement in execution over the past 12 months --- score 4.0

Management Trust (1)

1A: Factory continuous Improvement Deployment Actions are planned with targets annually, all KPI information is well extended to all levels L0: No formal Policy Deployment Plan exits

L1: Policy Deployment plan exits within the organization but is not

cascaded down to all levels

L2: PDP is formalized, includes specific Lean Objectives/targets, with

accountability for completion & timing extended through the entire

organization.

L3: L2 plus evidence of refinement over the past 12 months.

1B: The Factory Senior Managers are actively leading the Deployment of Lean Practices

(Senior managers are the senior managers on site at the location being

evaluated)

L0: No evidence of senior management leading or participating in

activities

organized

Kaizen

L1: Involvement consists primarily of periodic reviews/meetings in group

settings to review Lean targets

L2: Senior management participates fully in organized Kaizen activities.

L3: L2 plus evidence of improvement in execution over the past 12 months

1C: Meaningful Incentives that reward Organization & Individual Lean Progress are in Place

L0: No recognition of lean progress contribution exits within the

organization

L1: Recognition of lean progress contribution is present but not formalized, benefits are non financial.

L2: Members of the organization are recognized for & share directly and

individually in the financial benefits of Lean progress

L3:L2 plus evidence of improvement in execution over the past 12 months 1D: Policies & Agreements are in place and followed to protect the Income & working conditions of individuals made surplus by Lean Progress L0: No policies/agreements are in place

L3: Publicized Policies/agreements are in place and being followed with a

continuing history sufficient to establish stability & believability.

People (2)

2A: Lean Training during paid time is conducted for all individuals within the organization

L0: No Lean Training is made

L1: Lean Introduction and skill improvement training is made

L2: Formal Lean training Programs are conducted to all levels of the

organization with defined subjects. Training is scheduled, schedule is

followed, training effectiveness is measured.

L3:L2 plus evidence of refinement over the past 12 months

2B: Organization is structured to Correspond to the Structure of the Value Stream through the business

L0: Organization reports by function, without cross-functional

accountability

L1: Organization corresponds to the value stream but with limited cross-

accountability

functional

L2: Organization is structured that each function team is assigned within a defined value stream.

L3: L2 plus evidence of refinement or improvement in execution over the

past 12 months

2C: Team (CI/IE or another form of kaizen team—formal or informal) is organized and accountable for Continuous Improvement activities within their segment of the value stream

L0: No team organization/accountability exits

L1: Team organization is in place but with indefinite authority and/or

accountability.

L2: Team accountability is identified and has the authority to implement

activities with the full support of senior

improvement

continuous

Management

L3: L2 plus evidence of refinement over the past 12 months

Information (3)

3A: Data Collection and its Use are the responsibility of the Individuals Most Closely Associated with that Part of the Process and is shared across the organization

L0: Minimal or No Data is collected. Data is not accurate or is not available

L1: Data exits but is incomplete or difficult to access. Collection is

performed by non-operating personnel unassociated with that part of

the process/value stream

L2: Operating data accurate, recorded, analyzed and used by the

operating personnel responsible for the part of the process/value stream

L3: L2 plus evidence of refinement over the past 12 months

Supplier/Organization/Customer (4)

4A: Both suppliers (Tier 2) and customers (adidas) participate at the earliest possible stage and in regular reviews of the Development / Commercialization / Production'

L0: Neither customers & suppliers are included in the teams or process

review

L1: Occasional involvement by suppliers and customers in the team or review

process

L2: Both customers & suppliers (materials, chemical, machinery etc.) are

appropriately represented and participate in regular process reviews

L3: L2 plus evidence of refinement over the past 12 months

Product (5)

5A: Product engineering and production Process are Conducted by Fully Integrated Teams. Cost, technical performance Specifications are clearly understood, Measurable, and agreed by all Stakeholders (adidas, T1&T2).

L0: The component is not in place at all or there are some major

inconsistencies/contradictions in implementation

L1: The component is in place but there are some minor inconsistencies in implementation

L2: All stakeholders are represented on the product/process teams. Cost, technical performance specifications for product & Process are clearly

understood and agreed to by all stakeholders

L3: L2 plus evidence of refinement or improvement in execution over the

past 12 months

5B: Product & Process development fully adhere to DFM (Develop for Manufacturing), and are consistent with Lean Principles (shorten lead time & waste reduction).

L0: DFM is not in place at all or there are major

inconsistencies/contradictions in implementation

L1: DFM is in place but there are minor inconsistencies in implementation L2: Product development fully adheres to DFM, and are consistent with principles

Lean

L3: L2 plus evidence of refinement over the past 12 months

5C: Provision is made for Continuity of Team Knowledge for the Duration of Product/Process Launch

L0: No provision is made for the continuity of team personnel, document

control system is unreliable

L1: Continuity is dependent upon integrity of document control system,

some personnel continuity

L2: Provision is made for continuity of team knowledge for the duration of the product/process launch. Constancy of team personnel assigned is

maintained in addition to integrity of document control system.

L3: L2 plus evidence of refinement over the past 12 months

5D: Lead Times for Development/Comm. are Measured and being Continually Shortened.

L0: Development/Comm Lead times are not measured or do not undergo examination for improvement

L1: Development/Comm activities are measured by means of program

time line charting

L2: Development/Comm Lead times are formally measured and being

Shortened

Continually

L3: L2 plus evidence of refinement or improvement in execution over the

past 12 months.

Process Flow (6)

6A: The work environment is clean, well organized and audited regularly against Standardized 6S Practices

L0: Procedures are not in place or there are major inconsistencies in

implementation

L1: Procedures are in place but there are minor inconsistencies in

implementation or not followed

L2: 6S is fully in place, effectively implemented and followed with a

program

structured

L3: 6S program is fully in place, effectively implemented and shows

improvement in execution over the past 12 months.

6B: An effective Planned Preventative Maintenance System is in Place with the Appropriate Maintenance Conducted at the Prescribed Frequencies for All Equipment

L0: Maintenance is conducted on a breakdown basis only

L1: Some planned maintenance is conducted, no predictive maintenance

place

in

L2: An effective planned maintenance system is in place with the

appropriate maintenance conducted at the prescribed frequencies for all

equipment and predictive maintenance being practiced where appropriate L3: L2 plus evidence of refinement and improvement in execution over the past 12 months

6C: Specifications are accurately catalogued and Standard Operations are accurately routed, timed and have been value engineered.

L0: Specifications and/or standard operations are not recorded or in use

L1: Specification & SO in use but are inaccurate, missing or outdated.

L2: Manufacturing activities correspond to specifications & SO for the

complete process. Evidence of value engineering in Spec or SO present

L3: L2 plus evidence of refinement over the past 12 months

6D: Value stream is fully mapped and Products are Physically Segregated into product families

L0: Value stream is not defined or not recorded

L1: Value stream is partially or inaccurately mapped or lack of product

segregation is seen

L2: Up to date value streams are mapped for all product families, product

segregation is in place

L3: L2 plus evidence of refinement over the past 12 months

6E: Production Sequence is Load-Smoothed to Customer Pull, and Demand is leveled Over the Manufacturing Planning Period.

L0: Production scheduling is reactive to immediate customer orders

without regards to smoothing or leveling. Obvious fluctuations present in

levels and manpower requirements.

production

activity

L1: Some machines/cells load planning is done over a production planning period. Deviations from production plan occur regularly.

L2: Production sequence is load-smoothed to production plan, and

demand is leveled over the manufacturing planning period

L3: Production sequence is load-smoothed to customer pull, and demand is leveled over the manufacturing planning period

6F: Process Flow is controlled by Visual tools.

L0: No visual tools used in the process flow

L1: Partial implementation of visual controls

L2: Production activities are controlled by visible indicators within the

flow

process

L3: L2 plus evidence of refinement over the past 12 months

6G: Process is in statistical Control with Capability Requirements Being Met and Process Variability Continually Reduced

L0: Statistical methods not in use

L1: Some statistical recording done, Statistical tools not being used to

reduce process variability or to correct root cause of variability

L2: Process is in statistical control with capability requirements being met

and process variability continually reduced.

L3: L2 plus evidence of refinement over the past 12 months

6H: Preventative Action, using a Disciplined Problem Solving Method, is taken and Documented in Each case of Product or Process Nonconformance.

L0: No consistent method of root cause analysis is in use.

L1: Root cause analyses are performed but documentation is weak or

incomplete. Preventative action is inconsistent

L2: Preventative action, using a disciplined problem solving method, is

taken and documented in each instance of product or process

Nonconformance

L3: L2 plus evidence of refinement and improvement in execution over the past 12 months

6I: Production flow starts Only upon Receipt of shipment order. Process Flows at Takt Time Rate, in single unit Quantities.

L0: Pull techniques not in use

L1: Partial Implementation. Inventory accumulation present

L2: Process flows at takt time rate in single unit quantities throughout the stream.

value

L3: L2 plus evidence of refinement and improvement in execution over the past 12 months

6J: Procedures are in Place and Being Followed that Result in Continually Shorter Changeover times and smaller lot sizes.

L0: Changeover procedures and methods are not recorded

L1: Partial implementation

L2: Changeover activities are planned and executed in a consistent

manner. Changeover histories are recorded

L3: L2 plus continually shorter changeover times and smaller lot sizes

6K: Factory Layout Requires Continuous Synchronized Flow of Material and in Factory Product Travel Distance is Continually Reduced

L0: Process being conducted by batch method

L1: Flow exits but is not synchronized or work-in-process accumulation is

present, in excess of calculated minimum

L2: Flow is synchronized without excess work-in-process accumulation

L3: Demonstration of L2 plus evidence of successive reductions in product travel distance by flow path improvement

6L: Documented standard work methods and line balance techniques are used to distribute work evenly throughout the cell

L0: Use a standard work methods / Line balance not observed

L1: Standard work methods / Line balance are defined but loosely

followed or not displayed, or correctable imbalances in the worker loading observed.

are

L2: Accurate Standard work methods are displayed and followed at each

workstation, no obvious imbalance is observed.

L3: L2 plus evidence of successive redistribution of individual worker loads as either takt times or product are altered in response to changing order

demand.

adidas CI : Sept 2006