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Next StepsNext Steps

Jordan DentzJordan Dentz

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AssignmentsAssignments

1.1. Establish core continuous improvement team Establish core continuous improvement team (April 21)(April 21)

2.2. Current state value stream map (draft April 28; Current state value stream map (draft April 28; final May 14)final May 14)

3.3. Future state value stream map (draft May 19; Future state value stream map (draft May 19; final June 1)final June 1)

4.4. Develop plan (June 1)Develop plan (June 1)

5.5. Schedule RPI events (June 1)Schedule RPI events (June 1)

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1. Establish Core Continuous 1. Establish Core Continuous Improvement TeamImprovement Team

AssignmentAssignment

Provide details to MHRA team contact (April 21)Provide details to MHRA team contact (April 21)– Identify participants Identify participants

– Establish a weekly meeting schedule Establish a weekly meeting schedule

– Determine performance metrics to be collected (examples: Determine performance metrics to be collected (examples: rework, labor hours/floor, delays, etc.)rework, labor hours/floor, delays, etc.)

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2. Current State Value Stream Map2. Current State Value Stream Map

AssignmentsAssignments

Preliminary draft Preliminary draft (April 28)(April 28)

Revise and rework Revise and rework based on feedback based on feedback (May 14)(May 14)

Conduct detailed Conduct detailed analysis on selected analysis on selected processesprocesses

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2. Current State Value Stream Map2. Current State Value Stream Map

Share information with the MHRA team as it is Share information with the MHRA team as it is collectedcollected

The team will visit the plant to review progress The team will visit the plant to review progress and confer with the plant’s lean advocatesand confer with the plant’s lean advocates

Finalize current state map with MHRA team Finalize current state map with MHRA team inputinput

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2. Current State Value Stream Map2. Current State Value Stream Map

Identify from the value Identify from the value stream map specific stream map specific areas of improvementareas of improvement

In each area, conduct In each area, conduct detailed observations, detailed observations, create process flow create process flow maps, and collect maps, and collect quantitative dataquantitative data

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3. Future State Value Stream Map3. Future State Value Stream Map

AssignmentAssignment

Preliminary draft (May Preliminary draft (May 19)19)

Revise and rework Revise and rework based on feedback based on feedback (June 1)(June 1)

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3. Future State Value Stream Map3. Future State Value Stream Map

Develop a future-state value stream map, Develop a future-state value stream map, focusing on high priority, high return lean focusing on high priority, high return lean improvementsimprovements

Potential improvements will likely include: Potential improvements will likely include: – Workplace organization and standardizationWorkplace organization and standardization

– Labor optimization Labor optimization

– Better tools and equipmentBetter tools and equipment

– ProceduresProcedures

– Information systemsInformation systems

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3. Future State Value Stream Map3. Future State Value Stream Map

Review and refine the future-state value stream Review and refine the future-state value stream mapmap

Identify candidate lean improvementsIdentify candidate lean improvements

Create a short list of candidate lean Create a short list of candidate lean improvements that will form the basis for the RPI improvements that will form the basis for the RPI eventsevents

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4. Develop Plan4. Develop Plan

AssignmentAssignment

Develop plan for lean improvements (June 1)Develop plan for lean improvements (June 1)– Strategy for implementing lean improvements as depicted Strategy for implementing lean improvements as depicted

on the future-state value stream mapon the future-state value stream map

– Base the plan on conducting three or more RPI eventsBase the plan on conducting three or more RPI events

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4. Develop Plan4. Develop Plan

Each RPI event will be carefully planned, Each RPI event will be carefully planned, including:including:– what is to be accomplishedwhat is to be accomplished

– how the event will be conductedhow the event will be conducted

– resources and materials are neededresources and materials are needed

– plant personnel that will be involvedplant personnel that will be involved

Floor supervision and operators must be Floor supervision and operators must be involvedinvolved

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4. Develop Plan4. Develop Plan

The advocates and the advisory team will jointly The advocates and the advisory team will jointly draft the plan for the first RPI eventdraft the plan for the first RPI event

It will likely focus on workplace organization and It will likely focus on workplace organization and standardization (5S), since this serves as the standardization (5S), since this serves as the foundation for future lean improvementsfoundation for future lean improvements

Plans for subsequent RPI events will be drafted Plans for subsequent RPI events will be drafted by the advocates and reviewed by the advisory by the advocates and reviewed by the advisory teamteam

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5. RPI Events5. RPI Events

AssignmentAssignment

Submit requested RPI schedule dates (June 1)Submit requested RPI schedule dates (June 1)– Allot one week for an RPI eventAllot one week for an RPI event

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5. RPI Events5. RPI Events

The MHRA advisory team will work with the lean The MHRA advisory team will work with the lean advocates in conducting three RPI eventsadvocates in conducting three RPI events

The RPI events will initially be led by the MHRA The RPI events will initially be led by the MHRA advisory teamadvisory team

This responsibility will be shifted to the plant’s This responsibility will be shifted to the plant’s lean advocates in subsequent RPIslean advocates in subsequent RPIs

The goal is to transfer the expertise in facilitating The goal is to transfer the expertise in facilitating the process of continual improvement to plant the process of continual improvement to plant staff staff

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5. RPI Events5. RPI Events

One or more members of the advisory team will One or more members of the advisory team will be in the plant for each of the three RPI eventsbe in the plant for each of the three RPI events

RPI events will be documented and evaluated by RPI events will be documented and evaluated by the advisory team with the assistance of the the advisory team with the assistance of the advocatesadvocates

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5. RPI Events5. RPI Events

Results will be reported to plant managementResults will be reported to plant management

The evaluation will focus on: The evaluation will focus on: – RPI accomplishmentsRPI accomplishments

– Factors that limited RPI successFactors that limited RPI success

– Barriers that inhibit the development of a lean cultureBarriers that inhibit the development of a lean culture

– Further opportunities for improvementsFurther opportunities for improvements

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5. RPI Events5. RPI Events

Advocates will be encouraged to conduct Advocates will be encouraged to conduct additional RPI events between advisory team additional RPI events between advisory team visitsvisits

The future state map can include the additional The future state map can include the additional RPIs or they may be conducted as follow-ups to RPIs or they may be conducted as follow-ups to previous RPIsprevious RPIs

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5. RPI Events5. RPI Events

5S Evaluation Sheet5S Evaluation Sheet

RPI Event GuidelinesRPI Event Guidelines

Time Observation SheetTime Observation Sheet

Process Design Analysis SheetProcess Design Analysis Sheet

RPI Event Area Selection MatrixRPI Event Area Selection Matrix

RPI Materials and Equipment ChecklistRPI Materials and Equipment Checklist

RPI Event Preparation Checklist – By ActivityRPI Event Preparation Checklist – By Activity

RPI Event Preparation Checklist – By Time FrameRPI Event Preparation Checklist – By Time Frame

RPI Event ScheduleRPI Event Schedule

RPI Event Evaluation FormRPI Event Evaluation Form

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6. Final team meeting6. Final team meeting

After completion of all After completion of all RPI events, the lean RPI events, the lean advocates from all advocates from all plants and the MHRA plants and the MHRA advisory team will advisory team will convene for a one-convene for a one-day de-briefing where day de-briefing where participants will share participants will share experiencesexperiences

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Thank YouThank You

and good luck.and good luck.