Understanding What a Daily Management System Board Conveys

What does this scoreboard immediately tell us?

We can see the score is close with only 14 seconds left in the game. The team with the ball is losing and is on the 13-yard line with one timeout left.  The scoreboard is not clear on which 13-yard line (it was the winning teams 13-yard line). Based on the information, the losing team has 2 or 3 plays to win or tie the game. To summarize, this board conveys lagging information that only indicates results.  

Daily Management Systems and Football

Let us dig deeper into this game. Here is a look at the box score with yardage statistics for the game. 

We can see which players advanced the ball, scored, and turned the ball over.  The team stats show performance in specific categories. This detail allows for coaches to isolate strengths and weakness in the team, units, and some individual players.  Coaches have access to this data throughout the game. 

With this data available why is it hard for a coach to change his team’s performance during the game? Why can’t the coach just tell the Defense to quit letting the other team’s offense pass the ball? Or tell the offense to score more? The answer comes from my former football coach “The hay is already in the barn.”   

Once the game starts there is not much a coach can do to improve his team’s performance. The coach can adjust, tweak play calling and use motivating words/phrases to improve the performance, but the gains are typically minimal.  “Putting the hay in the barn” refers to the preparation to win a football game. Leading up to the game did the players:

• Follow the nutrition plan
• Get enough sleep 
• Complete their workout routine
• Watch film
• Practice
• Study the game plan
• Avoid distractions

Those are the inputs to improving a football teams’ performance. 

The Crucial Components of a DMS Board

Winning and losing in manufacturing is directly correlated with winning or losing a football game. The Daily Management System (DMS) board indicates whether the site:

• Had everyone go home just like they walked in the door
• Did not make a product that was below customer expectations
• Missed any deliveries
• Stayed within the budget to make all the ordered products

Plant leadership is responsible for the performance of their team, just like the football coaches are for their team. It is important that leadership reviews the “score” or “stats” in a plant along with Reviewing the inputs that determine performance. 

Daily Management System boards should include metrics on:

• Safety
• Quality
• Setup
• Shutdown
• Process checklists

Is the audit performance around the process posted with findings reviewed at some frequency? Is the preventive maintenance process reviewed on a frequent basis? Does the DMS board include run charts or any Statistical Process Control?

How a DMS Board Improves Performance and Quality

To improve the results, leadership must put focus on the review and response to inputs. Not performing preventive maintenance is a surefire way to ensure breakdowns. Neglect of quality checks and process checks leads to out of specification product. If football players stop training, the team’s performance will slowly decline. The amount of work (PAIN) to get back to the previous level is much more than the amount required to maintain.  It is no different in a manufacturing site. Leaders have control of the manufacturing inputs. Once the numbers are posted leaders only have accountability for the results, they cannot legally or ethically change the numbers.

Look at what your site reviews on a frequent basis. In the cost meeting, is the amount of scrap charged reviewed?  Are the processes to prevent scrap reviewed? See if the focus is more lagging results or more leading inputs. I would encourage you to change the management process towards leading inputs. If the recipe for success is followed the result will be success.

Are you ready to win the game? Contact Performance Solutions by Milliken  to see how we can work with your organization to build and implement a robust Daily Management System.