The Total Plant standard

Based on four principles of success Process mapping Fail-safing Teamwork Communication

Process mapping
Model flow of any business process in a graphical form Creates a common language for dealing with changes to business processes

Facilitator conducts process mapping training

Training philosophy at Honeywell focuses on educating employees about the importance of Total customer satisfaction world-class manufacturing

At Honeywell, process mapping consists of EIGHT steps

Select process lists the products customers for each product are identified teams are intensively trained in interviewing, data collection, & data analysis techniques Identify boundaries Input to output document boundaries for each product Form teams who is involved in creating the product

 Develop ``as is map represents the transformation of inputs into finished products includes information and product flow
Identify cycle times determined by measuring both a) distance the product travels through its process b) time required for performing the steps in the process Identify opportunities for improvement That would not add resources or extra costs

 Develop ``should be map

Improved processes & projections of their new cycle times

Develop the implementation plan

team prioritizes opportunities for improvement based on quality establish confirmation from steering committee

Fail-safing
Identify a defect, analyze to understand root cause & then develop a solution Guarantees that a process will be defect-free Tool at honeywell
The PDCA cycle Plan, do, check, act