w3 business systems w3 group, llc sfm kata connection mlc conference 2014

W3 Business Systems W3 Group, LLC

SFM Kata Connection

MLC conference

2014


Team Member Perform work to current standard Maintain 5-S in their work area Perform routine minor maintenance Look for Continuous Improvement

opportunities Support Problem Solving small group

activities

Team Member Perform work to current standard Maintain 5-S in their work area Perform routine minor maintenance Look for Continuous Improvement

opportunities Support Problem Solving small group

activities

Roles & Responsibilities

Team Leader• Process start-up and control• Meet production goals• Respond to TL calls by TM• Confirm quality - routine checks• Cover absenteeism• Training and cross-training• Work orders for quick maintenance• Insure Standardized Work is followed• Facilitate small group activities• On-going Continuous Improvement

projects• Insure parts / materials are supplied to

process

Team Leader• Process start-up and control• Meet production goals• Respond to TL calls by TM• Confirm quality - routine checks• Cover absenteeism• Training and cross-training• Work orders for quick maintenance• Insure Standardized Work is followed• Facilitate small group activities• On-going Continuous Improvement

projects• Insure parts / materials are supplied to

process

Group Leader• Manpower / vacation scheduling• Monthly production planning• Administrative: policy, attendance,

corrective actions• Team morale• Confirm routine quality and TL checks• Shift to shift coordination• Process trials• TM development and cross-training• Report / track daily production results• Cost reduction activities• Process improvement projects :

productivity, quality, ergonomics, etc.• Coordinate major maintenance• Coordinate support from outside groups• Coordinate work with up-stream and

down-stream processes• Group safety performance• Help cover TL absence• Coordinate activities around major

model changes

Group Leader• Manpower / vacation scheduling• Monthly production planning• Administrative: policy, attendance,

corrective actions• Team morale• Confirm routine quality and TL checks• Shift to shift coordination• Process trials• TM development and cross-training• Report / track daily production results• Cost reduction activities• Process improvement projects :

productivity, quality, ergonomics, etc.• Coordinate major maintenance• Coordinate support from outside groups• Coordinate work with up-stream and

down-stream processes• Group safety performance• Help cover TL absence• Coordinate activities around major

model changes


Kata Connection

Shop Floor Management

Policy Deployment

Continuous Improvement

Mini-companiesGlass wallsOwnership at the processLean ToolsStandard workEtc…

Hoshin KanriManagement by PlanningAnnual Goals & ObjectivesOrganizational engagement & alignment

A3 Problem SolvingSix SigmaValue Stream MapsToyota Kata


SFM Structure/Alignment

Operator Team Leader ManagerGroup Leader

External Coach

PARTICIPANTS

The degree of involvement of the coach is dependent on the SFM’s degree of maturity. While being a frequent observer in the beginning, the coach will slowly reduce the amount of involvement.


Traditional Organization

Plant Manager

General Supervisor

Supervisor

Value-Add Operator

DIR

EC

TIV

E


Future State Organization

Manager

Group Leader

Team Leader

Team Members

SU

PP

OR

TIV

E

Maint Pur PC ME Trans Quality WhseBPS



?

! !!

Daily

Monthly

Weekly

Reflection & Feedback

Weekly

Monthly

Monthly

Reflection & FeedbackSFM Routine

TEAM LEVEL


Daily SFM Coaching Routine

1. Safetylast 24h / next 24h

2. Attendancelast 24h / next 24h

How much capacity do we need and have?

Are people working where we need them?

3. Qualitylast 24h / next 24h

Where are we in relation to the goal? (KPI)

4. Costlast 24h / next 24h


5. Deliverylast 24h / next 24h


ProblemDid we understand the problem?

Can you explain the problem?Do we need to go & see to fully

understand?What can we do immediately?

Do you see any benefit in writing this down?

What can I do to help?How can I help?

REV 2.2

Use questions to inquire about the problem (examples)

Go and See as much as you can.

If you encounter:

= No issue, move on to next point of the routine

= Move to the problem section , investigate



?! !

!

Daily

Monthly


Monthly

Reflection & FeedbackSFM Routine

DEPARTMENT UNIT LEVEL


















REV 2.2



If you encounter:





?! !

!

Daily

Monthly


Monthly

SFM Routine

PLANT LEVEL


















REV 2.2



If you encounter:




1. Inquire Status 2. Answer

4.(Go&See) 3. Documentation

SFM Routine

?

!!

!


SFM Routine

TEAM LEVEL

Learning and reflection through observation

Learning and reflection through observation


















REV 2.2



If you encounter:




Phases During the SFM Coaching Routine

1. SFM Coaching Routine

?!

2. Clarification / feedback round

3. Summary and Expectation

4. Feedback from 2nd Coach

Learning through observation and self

reflection

What can we expect

to see tomorrow?

Learning through practicing the routine

Learning through feedback and self

reflection

This was my

impression….

Focus


Our Intent Today…

17

• To demonstrate

the core routines

of TK,

• give you

something

to think about

and…

• allow you to

compare to your

current way of

working.

© Mike Rother


C O

A C

H I

N G

K

A T

A The Five Questions1) What is the Target Condition?

2) What is the Actual Condition now?----------------- Turn Card Over ------------------>

3) What Obstacles do you think are preventing you from reaching the target condition?Which One are you addressing now?

4) What is your Next Step (next PDCA/experiment)What do you Expect?

5) When can we go and see what we have learned from taking that step?

© Mike Rother

Reflect on the Last Step Taken

1) What was your Last Step?

2) What did you Expect?3) What Actually Happened?4) What did you Learn?

Return --------->

Because you don’t actually know what the result of a step will be!

-------- Turn Card Over --------

Second Cycle and Beyond


















REV 2.2



If you encounter:




Our Intent Today…

24

• To demonstrate

the core routines

of TK,

• give you

something

to think about

and…

• allow you to

compare to your

current way of

working.

© Mike Rother

w3 business systems w3 group, llc sfm kata connection mlc conference 2014

Documents

w3 business systems

standardized work

work area

crosstraining work orders

routine quality

quality routine checks

tl checks

routine minor maintenance