The Power of Silent Brainstorming 2015 Automotive Symposium
Transcript of The Power of Silent Brainstorming 2015 Automotive Symposium
The Power of Silent Brainstorming
2015 Automotive Symposium Jd Marhevko,
MBB, ASQ Fellow, CSSBB,
CMQ/OE, CQE, VP QLMS/EHS, Accuride Corp, Past-Chair ASQ QMD
Learning Objectives
Across this time we will…
• See how this quality and lean tool can be applied to a
transactional process
• Increase your understanding of the power of silent
brainstorming
• Learn how to apply the tool in a live environment
Define
A traveling team of instructors trained customers on
the use of newly purchased product. Overall costs
exceeded $600K a year. Main costs included:
• Personnel time to coordinate the events
• Location site expenses
• Training materials
• Car rental/taxi for trainers
• Attendee food and beverage
An average event cost $50K and had excessive
variation. The process was not standard.
Measure
A key output measure was the overall expense. A moving
X (mX) graph was generated to review the history.
s
Target of $25K
Analyze
The team created a Value Stream Map (VSM) of the flow.
They then held a “silent” brainstorming session by using
“piggy-backed” Post-Its. Lessons Learned included:
• Logistics planners needed
a standard process.
• Previewing the cost Pareto
helped to shape approach.
Logistics Planning
Training Materials Coordinated
Personnel Identified
Dates/Timing Established
Deliver Personnel/ Materials; Hold Training
Idea 1 Idea 1 Idea 1
Idea 2 Idea 2
Idea 3
Analyze
Brainstorming ideas were sorted into affinity groups. An
assessment of ease of implementation vs impact was
conducted. Multi-voting was then used to prioritize the items.
Easy Difficult
Implementation
Im
pac
t (>
$1
0K
)
Lo
w
H
igh
• Video Std Work
• Sharepoint file for
vendors/locations
• Host @ Colleges
• Local Food/Bev
• Reduce car rental;
Transport w/Locals
• Train @ Customer site
• Ensure company room rates
in the area w/hotel properties
Room Exercise
• We will conduct our own silent brainstorm
• Q…How should you start to implement a QMS?
Record one idea to a Post-It. Print clearly
Write a “1” on it and pass it as directed
Receive the 1st idea
Review the idea and add a refining thought to it
Write a “2” on the note, attach it to “1” and pass it as
directed
Receive the 2nd idea
Review the 1st and 2nd idea on the note, add a refining
thought to it. Write a “3” on the note
Affinity or Group the ideas into common themes
Room Exercise
• Need volunteers to sort the “triple” notes into
clusters of affinity groups
• Title the groups
• Discuss: How might the “Silent” treatment might
impact the types of ideas?
• Discuss: What are the pros/cons of silent
brainstorming?
Improve
An aggressive 4 week timing plan was established:
• The team
consensed on the
actions to be taken.
• Standard work was
developed via video.
• Finance reviewed
potential impacts.
All actions were
completed within 4-6
weeks of the event.
Control
A video of the new process was created and stored on a
shared system. The team watched it via WebEx for
training. Before and after metric
after feedback was
provided to both
the coordinators
and trainers.
Personal objectives
were tied to formal
HR goals.
Team Take-Aways… After 3 months, the team met to review the process:
• Initial Kaizen session was completed in 2 days.
• It was ok to use input data thought to be ~70-80% accurate.
• An ice-breaking exercise on listening prior to the start of the
session was considered very valuable.
• Actions were implemented across 4-6 weeks.
• Video was a powerful form of “instant” standardization
across geographic regions.
• Finance team was included in impact assessment
• No personnel were negatively impacted by the effort.
Absorption of team members into growth areas enabled
new business to be conducted without adding personnel.
• Would they have achieved this w/o the 50% goal?
Transparency: Final Results
After 3 months, an annualized impact of $300K was
estimated. Hard: $200K. Soft: $100K.
Learning Objectives
In this session we have…
• Seen how this quality and lean tool can be applied to
a transactional process
• Increased your understanding of the power of silent
brainstorming
• Learned how to apply the tool in a live environment