Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One...
Transcript of Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One...
![Page 1: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/1.jpg)
Journey to Excellence 2019
![Page 2: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/2.jpg)
Driving Continuous Improvement through
Kaizen
Frank Walsh, Anita Dal PortoTrenchard Aviation
![Page 3: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/3.jpg)
72 Global Kaizen Events achieved over 18 months with 5 Facilitators
It works every time with any culture
![Page 4: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/4.jpg)
How to run a Kaizen
![Page 5: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/5.jpg)
Kaizen Agenda: 30 days before, 30 days after
Day 1 Day 2 Day 3 Day 4 Day 5
Plan = 30 days before Sustain = 30 days after
• Select an area with POTENTIAL!
• Choose a team: CROSS FUNCTIONAL
• Get senior management support.
• Ensure all data needed for current and future state analysis is available.
• Order all material in advance for work place re-organisation.
Kaizen Event• 30-day plan: if it
doesn’t get done in 30 days it doesn’t happen.
• Monitor results.• Review brainstorming
and priority quad for long term projects/Capital projects.
![Page 6: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/6.jpg)
Kaizen Agenda: The event
Day 1• Introduction
• Training• Current state
Analysis• Gemba
Day 2• Brain storming• Prioritization• “action plan”
Day 3• Team morning
briefing• Try-storming
• New standards development
Day 4• Team morning
briefing• New standards
development• How to hold the
gains
Day 5• How to hold the
gains• Team action plan
& Internal team handover
• Final presentation
![Page 7: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/7.jpg)
Kaizen Agenda: The event
Day 1- TrainingVSM – Learning to see
5S
What can we tell from this scene?
![Page 8: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/8.jpg)
Don’t Forget the Saucer!
This Photo by Unknown Author is licensed under CC BY
![Page 9: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/9.jpg)
Kaizen Agenda: The eventDay 2 – Prioritisation & team selection
10
2
5
1
35
3
![Page 10: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/10.jpg)
Kaizen Agenda: The eventDay 3 – Doing the doing
Day 4 – The new way of working
StandardisationRevised savings
![Page 11: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/11.jpg)
Kaizen Agenda: The event
Day 5 – Present and celebrate
Senior teamShare the success
![Page 12: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/12.jpg)
10 rules of kaizen
1.There is No Rank among team members (One person,
One Vote)2. Keep an open mind to
change3.Change is good; more
change is better
4.Maintain a positive attitude
5.Nobody blames anyone for anything
![Page 13: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/13.jpg)
10 rules of kaizen
6. Respect each other 7. There is no such thing as a dumb question
8. Plans are only good if they can be implemented
9. Plans succeed only if the gains are sustained
10. There is no substitute for hard work
![Page 14: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/14.jpg)
Case Study
Airbase 28-29-30/05/2019
![Page 15: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/15.jpg)
Airbase KAIZEN EVENT
SF sewing cell efficiency and workplace re-organization.
28th – 30th May 2019
![Page 16: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/16.jpg)
The team
Nicoleta
16
NicoletaEmmaLizzieAnita EdAnn
Shane
![Page 17: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/17.jpg)
Why do we need a kaizen
Customers requirements not being achieved due to:
Area unorganized, no control of consumables, no clear identification of WIP orders (only MPS no visual),
Demand higher than current assumed capacity.
Late deliveries due to lack of organization (cell and planning).
17
Backlog of 606 curtains ~86 working days with current
capacity
![Page 18: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/18.jpg)
Why do we need a kaizenCustomers requirements not being achieved due to:
Excessive overtime to catch up.
Quality issues (rushing the work through) – get data
Dependency reliance on external supplier
18
1 hour per day is spent for re-
work.
![Page 19: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/19.jpg)
The journey
19
Airbase SF Kaizen event – May 2019
![Page 20: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/20.jpg)
Team 1 – Process improvement
![Page 21: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/21.jpg)
Curtain making process map
Set up for new order.C/T = 8 min
Cutting curtain to size.
C/T = 6 minJoin seams, side
seams Ironing
Marking and sewing header.
C/T = 40-70 minIroning
C/T = 8 min.Stud machine
C/T= 15-20 min
Marking hem sewing hem
C/T = 30-50 min
Over lockingC/T = 10 min
Sewing adjuster limiter and label
C/T = 30 – 40 min
Taking finished goods to inspectionC/T = 10 min
21
Total removed time ~ 20-30 min
![Page 22: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/22.jpg)
Spaghetti diagram before and after
22
Before After
Back and forth from ironing station and overlocking. Removal of cutting steps, double steps and walking to inspection.
![Page 23: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/23.jpg)
Team 2 – 5S
![Page 24: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/24.jpg)
5S process
De-c
lutte
r
5S R
ed ta
g ar
ea
WIP
visu
al m
anag
emen
t
Desig
nate
d ra
ils a
nd a
rea
![Page 25: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/25.jpg)
5S process
Crea
te st
anda
rds
Trai
n an
d di
spal
y
Audi
t in
plac
e &
are
a ow
nwer
ship
Revi
ewed
as p
art o
f the
DM
S
![Page 26: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/26.jpg)
Airbase Kaizen event
26
Kick-off meeting ideas
5S Team Planning Board
JFDI !
THE NEW FLOW
OLD NEW
![Page 27: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/27.jpg)
Airbase Kaizen event
27
‘Personalised’ desks, clutter, excess tooling and equipment underneath work stations
Organized work stations with tool inventories and 5S guidelines
Before After
![Page 28: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/28.jpg)
Airbase Kaizen event
28
![Page 29: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/29.jpg)
Airbase Kaizen event
29
No visual identification of ‘material flow’ WIP Areas introduced with 5S guidelines and incorporated into daily workflow (TM/TL/MNG)
Before After
![Page 30: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/30.jpg)
Airbase Kaizen event
30
Display board for Kaizen 30 Day Plan and temporarily for new Pre-Shift Checks & T-Card Slots
5S guidelines and incorporated into daily workflow (TM/TL/MNG)
![Page 31: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/31.jpg)
Results
![Page 32: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/32.jpg)
Kaizen event score cardPerformance Indicator Before After Event Improvement
Distance walked (steps) 361 120 66.7%
Cycle time (hr, min) 4hr 46 min per curtain
2hr 50 min per curtain 40.6%
Area house keeping/5S (%)
0 70
Curtain back log (production days)
86 working days 60 working days 26 working days
Lead time ( weeks) 8 weeks3 weeks 62%
32
What does this mean?!
![Page 33: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/33.jpg)
Next steps: monitor results and sustain3. Progress Summary
(*) ave last three weeks
Team KPIs Start Target Current (*) Gap Bridged
40 56.24 -246%-£ #DIV/0!
* only standard pleated and non pleated: no ties, no paper etc.
Curtain output* (pcs/week)
Savings (£/week)
WeekCurtain output*
(pcs/week)
Savings (£/week)
week 23
week 24
week 25week 26week 27week 28week 29week 30week 31week 32
KPI Trend
![Page 34: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/34.jpg)
Case Study
Flatwood
![Page 35: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/35.jpg)
35
Can be adopted for overall supply chain solution
TRANETRANE A O SMITH
FW
FWFW
FW
FW
![Page 36: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/36.jpg)
36
ScorecardCurrent New Change
Unit Cost (mat + lab)
€161.9 €146.6 -9.5%
Motor Inventory
£236.1K £103.7K -£132.4K
Duct Inventory
£8.3K £5.1K -£3.2K
Trips off bay 14 0 -100%
![Page 37: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/37.jpg)
Kaizen …………………………………………
……
It works !!
![Page 38: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/38.jpg)
Things to Remember• Choose your Pilot Area carefully
• Chose your Team carefully
• Invite the doubters
• Cross Functional Teams
• Don’t bite off more than you can chew
• Get buy in from entire management team
• Plan early projects carefully to ensure success
• Celebrate every success
• Make managers responsible for implementation
• Follow-up, follow-up, follow-up
• Have Fun!
![Page 39: Journey to Excellence 2019 pdf · 10 rules of kaizen 1.There is No Rank among team members (One person, One Vote) 2. Keep an open mind to change 3.Change is good; more change is better](https://reader033.fdocuments.us/reader033/viewer/2022052011/6026b28ccbac8e1e5017bd60/html5/thumbnails/39.jpg)
Questions?