Consulting Business Start-up Evaluation Progress Report #1

1. Consulting BusinessStart-up EvaluationProgress Report #1 EMMP Capstone Project Central Team 12-21-02

2. Agenda: • Initial Work Completed • Project Tools Created • Project Activities To Date • Attention Areas • Summary • Next Steps

3. Initial Work Completed: (Initial Project Proposal) Project Definition: Evaluate the start up of an engineering consulting business focusing on manufacturing improvements. • Deliverables include case study, business start-up analysis and validation study • Limited to 1,200 team work hours • Limited to $100 in expenses

4. Initial Work Completed: (Current Project Proposal) Project Definition: Evaluate the start up of an engineering consulting business focusing on manufacturing improvements. • Change Notice 1 – Redefine the organization structure from Functional to Matrix. • Change Notice 2 - Deliverables include case study and business start-up analysis (modify validation study) • Change Notice 2 - Limited to 700 team work hours (initial scope reduced from 1,200) • Limited to $100 in expenses

5. Initial Work Completed: (Schedule) Due to Change Notice 2 (reduce hours, modify validation study), major schedule revisions have occurred New schedule has been created to reflect these changes:

6. Project Control Tools Created: • Project Hours Spreadsheet • Master Revision Control Tracker (MRCT) • Change Notice Process • Schedule Update Process

7. Project Control Tools Created: • Project Hours Spreadsheet • Document created to track overall project time.

8. Project Control Tools Created: • Project Hours Spreadsheet • Process • After each task, team is responsible for communicating logged hours. • Process Owner • Jim Heimler is maintaining this log.

9. Project Control Tools Created: • Project Hours Spreadsheet • Current Status Task Task Running # Task Name Duration Totals Start Finish 26 Case Study 75.56 days 0 11/6/02 8:00 2/19/03 13:30 27 Brainstorm 5 days 0 11/6/02 8:00 11/12/02 17:00 28 Brainstorm Methodologies 20 15.5 11/6/02 8:00 11/8/02 16:00 29 Determine Methodologies for Review 5 5 11/8/02 16:00 11/9/02 16:00 30 Teleconference #1 5 5 11/12/02 12:00 11/12/02 17:00 31 Assign Methodologies for in Depth Study 2.5 1.25 11/9/02 16:00 11/12/02 13:30 32 Research Criteria and Research Activities 28 days 0 11/12/02 13:30 12/20/02 13:30 33 Establish deliverables (criteria) for methodologies study 15 7.25 11/12/02 13:30 11/15/02 13:30 34 Research Methodologies per establish criteria 70 63 11/15/02 13:30 12/12/02 13:30 35 Write Report for each Methodology 15 20 12/12/02 13:30 12/17/02 13:30 36 Present Individuals findings on each Methodology 5 15 12/17/02 13:30 12/19/02 13:30 37 Compile Team Reports 10 hrs 12/19/02 13:30 12/20/02 13:30 38 Develop Continuous Improvement Methodology 43 days 0 12/20/02 13:30 2/19/03 13:30 39 Analyze each methodology and determine best practices 5 hrs 0 12/20/02 13:30 12/21/02 13:30 40 Compile best practices and formulate our own CIM 50 hrs 0 12/21/02 13:30 1/18/03 13:30 41 Determine the most appropriate communication method 10 hrs 0 1/18/03 13:30 1/22/03 13:30 42 Complete final Case Study document 100 hrs 0 1/22/03 13:30 2/19/03 13:30 43 Case Study Approval 0 hrs 0 2/19/03 13:30 2/19/03 13:30 * TOTALS 137.5 132 DIFFERENCE 5.5 Positive Variance * Does not include Administrative Time

10. Project Control Tools Created: • Master Revision Control Tracker (MRCT) • Source of the current status of project documents • Revision control log

11. Project Control Tools Created: • Master Revision Control Tracker (MRCT) • Process: • Maintained by one person • Process owner: Tron Melzl

12. Project Control Tools Created: • Change Notice Process • If an aspect of the project requires a major change is scope, quality or timing, a process has been put in place to address the concern. • First all team members need to discuss and approve. • Submit per our Communication Plan Matrix.

13. Change Control Form (CCF) Project Name UWM EMMP - CENTRAL CAPSTONE PROJECT Requestor Central Team Request Date 11/5/02 Description (What and Why) Change from 1200 total team hours to 700 total team hours. Scope determined too large. Looked at available resources and required resources for project and found significant mismatch. While targeting 700 total hours, the Validation study was dropped from the scope and the Business Case study was amended to reduce total hours. A Validation Plan will be added. Potentially Affected Stakeholders Governing Body Project Sponsor Potential Impact of Request Revision to master proposal Need Approval Project Control Tools Created: Requestor Information

14. Change Request Number Impact From Action Above Approved Project Manager Denied 002 Central Team Date Project Sponsor Impact Assessment performed by: Proposal must change and be re approved Schedule must change to reflect new work load. Lessons Learned Assessment (scope, timing, budget, resources, other) Resources more in line with reality. Governing Body (if required) Affected Stakeholder comments Project Control Tools Created: Project Manager Information Follow Up Action

15. Project Control Tools Created: • Change Notice Process • Process Owner • Team unanimously agrees to change and Tony Sciortino writes and submits paperwork for approval. • Current Status • CN001 Approved • Update proposal on organizational structure. • CN002 Approved • Revise plan to 700 total hours (modify Validation Study)

16. Project Control Tools Created: • Schedule • Based on time sheets, task hours are recorded when complete in baseline schedule. • Actual completion dates are also recorded. • These two data points measure team effectiveness.

17. Project Control Tools Created: • Schedule • Process Owner • Team to turn in data and Tony Sciortino to report out to team and others status to plan. • Team to determine and execute any actions if required.

18. Project Control Tools Created: • Schedule • Current Status

19. Project Control Tools Created: • Budget • A $100 budget was set up at the beginning of the project for incidentals. • No budget forecast. • No spending to date.

20. Project Activities To Date: • Choosing Research Methodologies • Compiled industry continuous improvement methodologies. • Broken down into description, steps, tools, etc. • Choose methodologies applicable to our business environments and interests.

21. Project Activities To Date: • Choosing Research Methodologies • Six Sigma • Lean Manufacturing • Quick Response Manufacturing (QRM) • Demand Flow Technology (DFT) • Focus PDCA Model • Total Quality Management (TQM) • Quality Education System • PACE • Theory of Inventive Problem Solving (TRIZ) • Achieving Competitive Excellence (ACE) • Re-engineering

22. Project Activities To Date: • Research Criteria Defined • I. Summary • II. Processes • III. Deliverables • IV. Tools • V. Ease of Implementation and Sustainability in any Manufacturing Setting • VI. Miscellaneous

23. Improve Control Analyze Define Measure MAKE THE CASE FOR ACTION LEARN ABOUT THE “Y” SUSTAIN THE SOLUTION LEARN ABOUT THE “X’s” PROVE THE SOLUTION Project Activities To Date:(Lean, Six Sigma, TRIZ Macro Summary) EHS Review FMEA P-R Analysis P-Q Analysis Pre-work/Kick-off Checklists Complete Takt/Cycle Time Bar Chart Innovation Situation Questionnaire,( ISQ) Substance Field Analysis (Su-field Analysis) Value Stream Map Define Project Scope Area Waste Assessment -Excess Travel Distance -Multi Touch/Handoffs -High Defect Rate -High Costs -Excessive Inventory -Excessive Lead Time Define Project CTQs (Goals & Objectives) Define Project Team Obtain Pledge Contract Enter Project Into Six Sigma Works Innovation Situation Questionnaire, (ISQ) Sub-Y Selection -Distance Traveled (Ft) -Floor Space (Ft2) -# of Touches -Mat. Handling/Ergo (#) -Quality Defects (DPMO) -RIP/WIP/FG Inv. (ICV$) -Cycle Time (Minutes) -Lead Time (Minutes) Gage R&R Target Sheet (Existing Process) Standard Worksheet (Existing Process) Std. Work Comb. Sheet (Existing Process) Pugh Matrix Target Sheet (New Process) Before & After Photos Standard Worksheet (New Process) Std. Work Comb. Sheet (New Process) Document Lessons Learned Create Action Item List Pitchout Checklist Complete Primary Functions, (PHF & PUF) Ideal Design Analysis Contradiction ARIZ Solution Implemented & Verified All Action Items Closed Quickplace Updated With Kick-off/Pitch-out Pages List of Issues For Future AWOs Created SOPs/OMSs Updated Update/Close Project In Six Sigma Works Ideal Design Analysis Su-field Analysis Patterns of Evolution KEY: Lean Six Sigma TRIZ

24. Attention Areas: • Barriers To Overcome • Issue • Data Storage • Meeting Agenda/Minutes • Schedule • Master Revision Control Tracker • Change Notice Process • etc. • Possible Resolution(s) • Common Folders • Write access to Blackboard (or equivalent)

25. Summary: • Time, Cost, Deliverables PROJECT OBJECTIVES BUDGET ACTUAL DIFFERENCE ACTIONS Time (hrs) 137.5 hrs 132 hrs + 5.5 hrs none req'd Completion Date 12/18/02 12/16/02 + 2 days none req'd Cost $100 $0 + $100 none req'd Performance none req'd All Deliverables Complete per Schedule

26. Next Steps: • Develop Continuous Improvement Methodology • by 2/19/03 • Complete Case Study Phase • by 2/19/03 • Begin Business Start Up • by 2/03 • Schedule Progress Report #2 • 2/03

27. Questions: