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Midwest Kata Practitioner Day
January 5, 2017
Safety Guidelines for Today
• Emergency Exits
• Bathrooms
Midwest Kata Practitioners Day
Reminders
• Presentations will be available for
download after today’s event
• Hold all Q&A for the Discussion/Q&A
sessions on the agenda
• Be sure to network today!

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Why KPDs?
KataCon 3
The 3rd
Annual Kata Summit
San Diego, California February 21-22, 2017
Brought to you by
Are you ready for this?
Calling all Improvement Kata / Coaching Kata practitioners, and those who
would like to be! Whether you were part the first or second Summit or not,
Improvement Kata and Coaching Kata users. The Summit emphasizes
experiential learning so practitioners, trainers and consultants can integrate
practice of the IK/CK routines into their teams and organizations. This
conference goes beyond concepts by equipping attendees to train and
practice at home.
A supplementary accessible, compact, regional
forum for sharing IK/CK activity
Two passes will be given away at the end of today!
KPD - Purpose
• Learn more about Improvement Kata /
Coaching Kata
• Share experiences with making scientific
thinking a practical skill that anyone can learn
through practice.
• See what Midwest organizations are doing and
learning with IK/CK practice
• Encourage Communities of Practice in the
Midwest
KPD - Desired Outcomes
• You have a better understanding of the IK/CK
approach to improvement, adaptation and
innovation
• You're thinking about scientific thinking
• You're inspired to help develop scientific
thinking in young people
• Interest in a Community of Practice
• Maybe we meet again
1) DIY
• Not just copying
• Practice the "Starter Kata,"
then evolve your own way
Improvement Kata Spirit
2) You're Part of It
• At the KPD – Pick up as much as you can
• After the KPD – Practice, and share what
you learn

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What’s Your IK/CK
Experience Level?
Newbie: Heard about Kata, want to learn
more, not yet practicing
Advanced
Beginner: Practicing for 2 or less years
Competent: Practicing for 2 – 4 years, Coaching
Proficient: Practicing for > 4 years,
Coaching and Teaching
KPD Agenda Overview
AM
• Keynote
• Overview of IK/CK
• Q&A / Discussion
• 20-Minute Break
• 3 Practitioners
• Q&A / Discussion
PM
• "Kata in the
Classroom" Exercise
• 20-Minute Break
• 3 Practitioners
• Q&A / Discussion
• Next Steps
LUNCH
(60 min)
Networking
9:00 - Start
12:00 - End
1:00 - Start
4:30 - End
Let's Get Started!
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January 5, 2017
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Behaviors Drive Outcomes
An organization’s collection of practices and
principles at any point in time is an outcome that
springs from its members’ routines of thinking and
behavior. Any organization’s competitiveness, ability
to adapt , and culture arise from the routines and
habits by which the people in the organization
conduct themselves every day. It is an issue of
human behavior.
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Toyota Research – 2 Questions
1. What are the unseen
managerial routines and
thinking that lie behind
Toyota’s success with
continuous improvement
and adaptation?
1. How can other companies
develop similar routines
and thinking in their
organizations?
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New Roots Consulting, LLC 2016
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“Let’s begin by practicing it this way for a
while”
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routines (Kata) develops effective problem solvers
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are Practiced to Develop Scientific Mindset
WHAT KATA ARE FOR
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each Learner can start to (within limits) develop their own style.
Likewise, over time each organization can evolve the Kata it began with
to better suit and mesh with its culture. The original Kata evolve into
organization-specific practice routines.
Kata
Practice
To develop
foundational
skill and mindset
By Mike Rother
(1) FOLLOW: Start by repeating each
practice routine without modification, so
you can absorb its fundamental pattern.
(2) DETACH: Once the basic patterns get
habitual and you understand the 'why'
behind them, you'll start to adapt them.
HOW LONG DO YOU PRACTICE
RELIGIOUSLY?
(3) FLUENCY: At this stage your
actions become natural. You can
create your own approaches to fit
different circumstances, while
sticking to basic underlying
principles.
Real practice doesn't pass through these discrete stages,
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+ THE COACHING KATA
It’s a methodology for developing people
to meet challenges
By Mike Rother
(Manager)
Improvement
Kata
Coaching
Kata
Understand
the
Direction or
Challenge
Grasp the
Current
Condition
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Condition
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Coaching
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THE IMPROVEMENT KATA
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By Mike Rother
(Manager)
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Kata
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Kata
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the
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THE IMPROVEMENT KATA
+ THE COACHING KATA
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(Manager)
Improvement
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Kata
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Current
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Target
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Condition
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‘Planning’ Coaching Cycles
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CONNECTING STRATEGY & EXECUTION
By Mike Rother 25
Vision
Next
Target
Condition
Current
Condition
Obstacles Challenge
Execution Strategy
Leaders establish the
organizations strategic concept
(the “rallying point” or overall
direction)
Managers develop people by
coaching application practice of
the Improvement Kata in the
direction of the challenge
The role of Challenge in an organization
Value Stream Mapping
5 min.
65 min.
8 min.
55 min.
2 min.
536 min.
9 min. 15 min.
53 min.
Pacemaker Loop
Planning Loop
New Roots Consulting, LLC 2016
Grasping the Current Condition
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• Standard Work
• Spaghetti Diagrams
• Data Analysis
• Going to See
New Roots Consulting, LLC 2016
By Mike Rother 28
ESTABLISHING TARGET
CONDITIONS
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• Break a big challenge down into smaller
goals.
• Set an easier and closer goal that's on
the way to your challenge. When you
get there you can set the next goal.
Key Points About:
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A CHALLENGE FOR THE COACH
The Learner should practice in a
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Go
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(Manager)
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A Pattern for Daily Improvement
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The document outlines a training for peer coaching, describing it as a process where experienced staff provide guidance and support to help new staff learn job functions. It discusses the roles and expectations of coaches, providing guidance and tools for setting goals, implementing a coaching cycle of focus, action, and reflection, and best practices for peer coaching. The training is intended to help new staff learn through collaborative guidance from more experienced peers.

#coaching
what is qc
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The document discusses quality circles (QCs), including their definition, structure, roles, and process. QCs are small voluntary groups of employees who work to continuously improve quality, productivity, safety, and morale. The roles of coordinators, facilitators, leaders, and members are outlined. Steps for problem solving using QCs are also provided.

qc
A Pattern for Daily Improvement
What actually happened? What
did you learn?
5
• What changed within the
process? (Look at the visual
tracking of the current
condition)
• What other things were
impacted? (Both for the
positive and negative)
• What was the impact to the
social environment?
• What did we learn by that
experiment?
New Roots Consulting, LLC 2016
A Pattern for Daily Improvement
• What is our current
condition now in relation
to our target condition?
• What obstacles did we
remove?
• What new obstacles did we
discover?
New Roots Consulting, LLC 2016
What obstacle did
we address? new
obstacles did we
uncover?
What is our
current
performance now in
relation to our
target condition?
6
A Pattern for Daily Improvement
What key problem are
you working on next? What
are you going to try? What
do you expect to happen?
7
• What will you experiment
with to address that
obstacle/root cause? How
did you come to that
decision?
• What do you expect to
happen? (Positive and
negative)
New Roots Consulting, LLC 2016
A3 and Kata
Background
Current Condition
Problem Statement:
Goals/Targets
Gap Analysis
Countermeasures
Follow Up
Plan
New Roots Consulting, LLC 2016

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These slides are from a webinar delivered by Deri Hughes, Honeycomb PS Founder and Consulting Skills Expert. Deri goes through the Honeycomb Consulting Skills Accelerator - a tried-and-tested toolkit to drive skill developing in professional services firms. By deploying this approach firms can add £500k profit per consultant over 5 years - by progressing their teams faster to get more leverage. There are 9 parts to the toolkit that Deri covers in the webinar: - Vision - Strategy - Capabilities - Team - Project Experience - Coaching - Training - Feedback - Measurement Get in touch if you want to know more (deri.hughes@honeycombps.co.uk)

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Coacharya programs
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This document provides an overview of Coacharya, a coaching service and training program. It describes Coacharya's 3C coaching process, AIDAA approach, CREATOR framework, and various coaching and leadership development programs. These include public coach credentialing programs, institutional programs like Coach To Lead and Barefoot Leadership, and personal development programs such as Create Your Future. Biographies of the co-founders Ram Ramanathan and Pranav Ramanathan are also provided, as well as a list of clients Coacharya has served worldwide in various industries.

SCIENTIFIC
THINKING
Scientific thinking is a routine of intentional coordination between
what we think will happen (theory), what actually happens
(evidence), and adjusting based on what we learn from the
difference.
What we
expect
to happen
What
actually
happened
Learning
"Let'stryitandsee"
By Mike Rother
THE IMPROVEMENT KATA
+ THE COACHING KATA
It’s a methodology for developing people
to meet challenges
By Mike Rother
Improvement
Kata
(Manager)
Coaching
Kata
Understand
the
Direction or
Challenge
Grasp the
Current
Condition
Establish
the Next
Target
Condition
Experiment
Toward the
Target
Condition
‘Executing’
Coaching
Cycles
‘Planning’ Coaching Cycles
Learner
Coach
THERE'S ALSO A COACHING KATA
A way of coaching. Toyota's Master-Apprentice style
teaching approach is like training in sports and music.
Together the Improvement Kata and Coaching Kata
make up a management approach
Learner
Coach
(Manager)
By Mike Rother
Coaching is…
As in sports and music, practicing should be done
under periodic observation and guidance of an
experienced coach. Without coaching we lose our
way and don’t practice the right pattern, or practice
ineffectively. Without coaching, a change in our
mindset -- in our brain's wiring -- is unlikely to occur.
Mike Rother

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Transformational coaching supervision webinar may 2014
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COACHING KATA
Developing New Habits
• By practicing a specific routine around ‘how’ you do
daily improvement and coaching, it becomes a habit
• Once you develop the habit, it can become a repeated
pattern of how you address problems toward improving
performance within your organization
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Roles / Org Structure for Practicing
Learner's
Storyboard
LearnerCoach
(Manager)
2nd Coach
Team
Practices the
Improvement Kata
Practices the
Coaching Kata
Coaches
the Coach
By Mike Rother
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+ THE COACHING KATA
It’s a methodology for developing people
to meet challenges
By Mike Rother
Improvement
Kata
(Manager)
Coaching
Kata
Understand
the
Direction or
Challenge
Grasp the
Current
Condition
Establish
the Next
Target
Condition
Experiment
Toward the
Target
Condition
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Coaching
Cycles
‘Planning’ Coaching Cycles
Learner
Coach

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This document discusses success consultations provided by the Student Success Center for new Resident Mentors and those on academic probation. It describes that new RMs must attend one consultation, while those on probation must attend three consultations focused on academic skill development. It provides the timeline for scheduling these mandatory consultations throughout the semester. It also introduces the Leadership Practices Inventory self-assessment that students can use to evaluate their leadership strengths and areas for improvement.

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ABOUT SERIGRAPH
Plastic printing, in-mold labeling & custom graphics company specializing in
decorative, functional & brand solutions
• Established: 1949
• Ownership: Private
• Headquarters: West Bend, WI – USA
• Employees: 750
• Plant Locations:West Bend, WI
Querétaro, Mexico
MARKETS
• Appliance
• Automotive
• Medical
• Power Sports / Outdoor Equipment
• Consumer Products
• Aerospace
• Sporting Goods
PRODUCT OFFERING
• In-mold labeling
• Decorative overlays
• Decals & labels
• Badges/nameplates
CORE COMPETENCIES
• Graphic Design
• Color Matching/Lighting Development
• Material Science
• Prototyping
• Printing
• Forming
• IML/IMD Molding
• Cutting
• Assembly
• Finishing
• Inspection
• Testing/Validation
• Vendor Managed Inventory (VMI)

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QUALITY MANUFACTURING
• TS* 16949 certified
• ISO 9001 certified
• ISO 14001** certified
• Lean/Six Sigma continuous improvement
system
• Fully equipped clean rooms
• In-house, TS-certified test facilities
MEXICO OPERATIONS
• Centrally located in Queretaro, Mexico
• Premier printer for Latin America & Mexico for 50 years
• Centralized design, local manufacturing
• Top quality manufacturing, equivalent to USA
• Continuous improvement/lean environment
• ISO/TS* 16949 certified
• ISO 14001** certified
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**Environmental certification
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Appliance
Handheld
Electronics/
Medical
Consumer
Goods
Custom
Graphics
Industrial
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The book "Unlocking the Human Element in IT" provides a comprehensive guide to understanding and leveraging the human aspects of information technology. Drawing on extensive research and real-world case studies, the book delves into the critical role that people, culture, and organizational dynamics play in the success or failure of IT initiatives. The Importance of the Human Element in IT The book begins by highlighting the often-overlooked human dimension of IT, emphasizing that technology alone is not enough to drive meaningful change and innovation. It argues that the true power of IT lies in its ability to empower and engage people, fostering a collaborative and adaptive organizational culture. Key Themes and Insights People-Centric Approach: The book underscores the need to shift from a technology-centric mindset to a people-centric approach in IT management. It explores strategies for aligning IT goals with the needs and aspirations of employees, customers, and stakeholders. Organizational Culture: The authors examine the profound impact of organizational culture on IT initiatives, addressing topics such as change management, leadership, and team dynamics. They provide practical frameworks for cultivating a culture that embraces innovation, collaboration, and continuous learning. Soft Skills and Talent Management: The book delves into the importance of developing soft skills, such as communication, empathy, and problem-solving, among IT professionals. It also explores effective talent management strategies to attract, retain, and develop high-performing IT teams. Agile and Adaptive IT: The book highlights the rise of agile and adaptive IT methodologies, emphasizing the need for IT organizations to be nimble, responsive, and customer-centric. It offers guidance on implementing agile practices and fostering a mindset of continuous improvement. Bridging the IT-Business Divide: The authors address the longstanding challenge of aligning IT with business objectives, providing strategies for enhancing collaboration, communication, and mutual understanding between IT and other organizational functions. Practical Applications and Case Studies Throughout the book, the authors present real-world case studies that illustrate the impact of the human element in IT. These case studies cover a range of industries and organizational contexts, offering valuable insights and lessons learned for readers to apply in their own environments. Conclusion "Unlocking the Human Element in IT" is a must-read for IT leaders, managers, and professionals who recognize the importance of people, culture, and organizational dynamics in driving successful IT initiatives. By embracing the human element, organizations can unlock the full potential of their technology investments and achieve sustainable, transformative change. People mentioned: - Matt Beran - Deborah Monroe - NJ Robinson - Megan Engels - Gregg Gregory - Rocky McGuire Learn more at invgate.com

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SERIGRAPH’S MANAGEMENT
SYSTEM
January 5, 2017
OVERVIEW
• Serigraph’s Continuous Improvement Journey
• Management System
– Tiered Dashboards
– MDI – SQDC
– Gemba – Coaching Kata
– Leader Standard Work
– Problem Solving
• Next Steps
LEAN
CERTIFICATION
2005
CONTINUOUS IMPROVEMENT JOURNEY
SIX SIGMA
TRAINING
2011
HOSHIN
KANRI
2012
2-SECOND
LEAN
2014
4-STEP
PROBLEM
SOLVING
2014
SERIGRAPH
MANAGEMENT
SYSTEM
2016
MANAGEMENT SYSTEM
– Make gaps visible
– Drive improvement through problem solving

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• TRUE NORTH
– What do we want to be?
• Tier 1 (monthly)
– Translates True North goals into
metrics
– Balanced dashboard, offsetting
metrics
– Not directly actionable
• Tier II (monthly, weekly, daily)
– Balanced dashboard and MDI
– KPIs to achieve Tier I targets
– Directional, not directly actionable
• Tier III (monthly, weekly, daily)
– Balanced dashboard and MDI
– KPIs to achieve Tier II targets
– Actionable – where the A3s live
• Tier IV (daily, hourly)
– Simple metrics
– Directly actionable
– Alert to the current situation
– Where ‘just do it’ problem solving
happens
DASHBOARD DEVELOPMENT
DASHBOARD DEVELOPMENT
Serigraph Inc.
IG - North America
Tier I Dashboard
True North: Solve Problems We Will
FY2016 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 FY2017 Gap Where Pareto Items (Row 1: Pareto Item Description; Row 2: Impact to Gap)
Actual $
Target $
Actual Days
Target Days
Actual Incidents 4 1 1 0 0 2 S0272M S0220S
Target
(LY)
Incidents 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Strain (occurred in
May 2016)
Slipped in lunch
room (elbow)
Actual # 326 39 33 16 13 101 Quality Color Lab Proj Mgmt
Target # 328 42 33 16 13 0 0 0 0 0 0 0 0 104 1 1 1
Actual %of Cost 13.3% 17.3% 15.0% 14.1% 11.7% 14.6% Visteon (3 Accts) M1182 Marquardt S1403 Continental
J1043M Jabil
Luxembourg
Target %of Cost 13.6% 12.0% 11.5% 11.0% 10.5% 10.0% 9.5% 9.0% 9.0% 9.0% 9.0% 9.0% 9.0% 11.3% 1.0% 0.5% 0.5% 0.2%
Actual PPM 1,221 672 293 4,465 2,035 1,326
Target PPM 1,916 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066
Actual % 93.0% 90.2% 89.5% 90.3% 88.9% 89.7%
Conti Guad
(85.4%; 158 late)
Visteon (14.0%;
104 late)
Calsonic (62.6%;
34 late)
Delphi (63.2%; 28
late)
Target % 96.5% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 2.7% 2.3% 0.7% 0.6%
Actual $,000 $54,741 $3,731 $4,572 $4,205 $3,823 $16,331 M1182 Marquardt R1178 RJR S1403 Continental G1044 GHSP
Target $,000 $65,770 $4,910 $4,806 $4,653 $4,811 $4,685 $4,825 $4,560 $4,040 $4,493 $4,211 $4,324 $4,014 $19,180 ($1,188) ($960) ($547) ($401)
Actual $ $33,798 $2,183 $2,864 $2,612 $2,406 $10,064 R1178 RJR S1403 Continental M1182 Marquardt H1016 Honda
Target $ $39,289 $3,093 $2,964 $2,867 $2,963 $2,893 $2,977 $2,864 $2,535 $2,826 $2,632 $2,715 $2,529 $11,888 ($651) ($468) ($434) ($304)
Actual % 61.7% 58.5% 62.6% 62.1% 62.9% 61.6%
Target % 59.7% 63.0% 61.7% 61.6% 61.6% 61.7% 61.7% 62.8% 62.8% 62.9% 62.5% 62.8% 63.0% 62.0%
Actual $,000 $31,446 $2,235 $2,576 $2,348 $2,467 $9,626
Target $,000 $32,959 $2,657 $2,733 $2,596 $2,655 $2,635 $2,865 $2,626 $2,348 $2,741 $2,397 $2,662 $2,538 $10,642
Actual $,000 $5,242 $125 $628 $1,068 $307 $2,128 Automotive Power Sports Appliance
Consumer
Products
Target $,000 $13,793 $900 $1,000 $700 $900 $1,000 $1,200 $1,200 $1,200 $1,200 $1,200 $1,200 $1,200 $3,500 $3,799 $2,575 $2,360 $1,926
Actual $,000 $8,534 $169 $1,031 $1,867 $497 $3,563 Automotive Power Sports Appliance
Consumer
Products
Target $,000 $22,934 $1,440 $1,600 $1,120 $1,440 $1,600 $1,920 $1,920 $1,920 $1,920 $1,920 $1,920 $1,920 $5,600 $5,892 $4,324 $4,069 $2,425
Actual % 61.4% 73.9% 60.9% 57.2% 61.8% 59.7%
Target % 60.1% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5%
Scrap (Internal Quality)
On-Time Personnel
Evaluations
People
Fixed Cost $'s
Sales (Excluding
Tooling)
(3)
-3.3%
Cost
Scrap (External Quality)
TrueNorth
Days Sales Outstanding
+ Days In Inventory (3
Month Rolling)
New Business Awarded
(FY2017 CM $)
P.O. Line Items Shipped
per Customer Request
Date
Safety (Lost Time +
Recordables)
Operating Profit
Delivery
Contribution Margin $
(Excluding Tooling)
Contribution Margin %
(Excluding Tooling)
GrowthQuality
New Business Awarded
(FY2017 CM %)
New Business Awarded
(FY2017 Annual Sales $)
(2) Operations
($1,372)
Top 3 customers
make up 60% of
our miss to YTD
target
Full Year CM$ Gap
($2,037)
Full Year Sales$
Gap
Accounts driving
Oct-16 late
deliveries
($2,849)
$3.096 of variance
with these 4
customers
($1,824)
$1.858 of variance
with these 4
customers
-6.3%
DASHBOARD DEVELOPMENT
Information
Help
Tier I
Tier II
Tier III
Tier IV
DASHBOARD DEVELOPMENT
• Suppliers, Inputs, Process, Outputs, Customers
• Worked with each functional area to determine their ‘output’ and the critical
requirements of each
– Launch & Engineering – Tooling and Routing
– Human Resources – Employees
– Sales – Statement of Work, Promise to Buy Parts
– Operations – Customer Parts
• Translate those critical requirements into metrics
S I P O CR R

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DASHBOARD DEVELOPMENT
Safety
Zone:
Metric:
Target:
29 30 31
28
15 16 17 18 19 20 21
22 23 24 25 26 27
7
8 9 10 11 12 13 14
1 2 3 4 5 6
Safety Incidents
IG Ops
0
Quality
Zone:
Metric:
Target:
IG Ops
<9%
29 30 31
21
22 23 24 25 26 27 28
15 16 17 18 19 20
7
8 9 10 11 12 13 14
1 2 3 4 5 6
Scrap % of Cost
Delivery
Zone:
Metric:
Target:
IG Ops
Ship Lines On Time
>97%
29 30 31
21
22 23 24 25 26 27 28
15 16 17 18 19 20
7
8 9 10 11 12 13 14
1 2 3 4 5 6
Cost
Zone:
Metric:
Target:
Utilization
IG Ops
> 62%
7
8 9 10 11 12 13 14
1 2 3 4 5 6
21
22 23 24 25 26 27 28
15 16 17 18 19 20
29 30 31
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
July Aug Sep Oct Nov Dec Jan Feb Mar April May Jun
Total
0Value
Safety Incidents
#ofIncidents
History
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
July Aug Sep Oct Nov Dec Jan Feb Mar April May Jun
Total
0Value
Safety Incidents
#ofIncidents
History
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
July Aug Sep Oct Nov Dec Jan Feb Mar April May Jun
Total
0Value
Safety Incidents
#ofIncidents
History
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
July Aug Sep Oct Nov Dec Jan Feb Mar April May Jun
Total
0Value
Safety Incidents
#ofIncidents
History
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
Issue#LineItemsLatebyCustomer
Miss Pareto
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
Issue#LineItemsLatebyCustomer
Miss Pareto
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
Issue#LineItemsLatebyCustomer
Miss Pareto
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
Issue#LineItemsLatebyCustomer
Miss Pareto
Status
Problem-Solving
Location
A3
Yes or
No
Identified By
Date
Identifie
d
Shift
Quantified Impact
on Gap
Due
Date
Assigned To
Date
Closed
1
2
3
4
5
6
7
8
9
10
11
12
13
Continuous Improvement Countermeasure Status
Issue Countermeasure Status
Problem-Solving
Location
A3
Yes or
No
Identified By
Date
Identifie
d
Shift
Quantified Impact
on Gap
Due
Date
Assigned To
Date
Closed
1
2
3
4
5
6
7
8
9
10
11
12
13
Continuous Improvement Countermeasure Status
Issue Countermeasure Status
Problem-Solving
Location
A3
Yes or
No
Identified By
Date
Identifie
d
Shift
Quantified Impact
on Gap
Due
Date
Assigned To
Date
Closed
1
2
3
4
5
6
7
8
9
10
11
12
13
Continuous Improvement Countermeasure Status
Issue Countermeasure Status
Problem-Solving
Location
A3
Yes or
No
Identified By
Date
Identifie
d
Shift
Quantified Impact
on Gap
Due
Date
Assigned To
Date
Closed
1
2
3
4
5
6
7
8
9
10
11
12
13
Continuous Improvement Countermeasure Status
Issue Countermeasure
Are we winning or losing?
By how much?
What are the top causes?
Are there people on it?
DASHBOARD DEVELOPMENT
GEMBA - PPO
• Purpose
– Take responsibility
– Drive Performance – understand how and when gaps will be closed
– Develop the problem solving capabilities of our people
– Reinforce our values and celebrate our wins
• Process
– Verify completion of previous commitments from last Gemba
– Review current red conditions and trends
– Review pareto data for direct causes
– Confirm issue is on countermeasure sheet
– Review/coach problem solving
• Outcome
– Plan for improvement (who and when)
GEMBA
• Coaching Kata
– What is the Target Condition?
– What is the Actual Condition now?
• Reflection on last step taken
– What Obstacles are preventing you from reaching your Target
Condition?
• Which ONE are you addressing now?
– What is your Next Step?
• What do you expect?
– How quickly can we go and see what we Have Learned from taking
that step?

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DASHBOARD DEVELOPMENT
Information
Help
Tier I
Tier II
Tier III
Tier IV
GEMBA - LEADER STANDARD WORK
Goals of Standard Work:
1. Seek Understanding
2. Set Expectations
1-Nov
2-Nov
3-Nov
4-Nov
7-Nov
8-Nov
9-Nov
10-Nov
11-Nov
14-Nov
15-Nov
16-Nov
17-Nov
18-Nov
21-Nov
22-Nov
23-Nov
24-Nov
25-Nov
28-Nov
29-Nov
30-Nov
Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F
Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F
1:00
2:00
3:30
1:00
8:00
9:30
3:30
Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F
Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F
9:30
all day
Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F
1day
Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F
August
Tier II Launch
Hoshin PDCA
Bi-Weekly
A3 Inventory
Tier I
Tier II Operations - M X
Populate SQDC
Annual
Review Scrap from Yesterday's Closed WOs
Open A3
Tier II Operations - WB
Tier I Dashboard Review
STANDARD WORK
Standard Work = What I do to obtain a
desired outcome
Weekly
NovemberSelect Month & Year:
Tier II Sales - CP/M D
2016
Gembas
Daily
Tier II Sales - Auto
Quarterly
Personal Goal Setting
EA M eeting
Monthly
Populate Tier II CI SQDC
Black Belt Project
Tier II Sales - Appl/PS
Pla
n
Do
C
heck
Act
Go
&
See
Pla
n
Do
C
heck
Act
Go
&
See
Pla
n
Do
C
heck
Act
Go
&
See
Pla
n
Do
C
heck
Act
Go
&
See
Pla
n
Do
C
heck
Act
Go
&
See
Pla
n
Do
C
heck
Act
Go
&
See
PROBLEM SOLVING
• To prevent recurrence of a problem by eliminating its cause
• You can give a person fish or…
4 STEP PROBLEM SOLVING
Problem Solving A3 Title
Step 1: DO I HAVE A PROBLEM? Step 3: DID I TEST FOR CAUSE & EFFECT?
a) What Should be Happening? a) Hypothesis: If _______________________________________________
b) What is Actually Happening? (How many? How often?) Then ___________________________________________
c) What is the Gap? b) Conduct Experiment(s)
c) Test Results:
d) What is the Impact?
What Happens? ____________________________________
e.) Problem Statement:
Why? ____________________________________________
Step 2: DO I KNOW THE CAUSE?
d) Select Countermeasures:
a) What is the Point of Cause?
b) What is the Direct Cause(s)?
(Show your work - Results of 5why, pareto, fishbone, etc) Step 4: DID I CONFIRM COUNTERMEASURES?
a) What standards / work instructions need to be updated?
b) How Will I Confirm a Good Condition?
C) Who Will Check?
c) What is the Root Cause(s)? d) How Frequent?
e) How Long Will I Check?
Plan Do Check Adjust Team : Start Date
Last Activity
Control
Define Improve
Analyze

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NEXT STEPS
• Maintain consistency of kata during gembas
• Improve our bench strength in coaching problem
solving
• Celebrate the wins
Midwest Kata Practitioners Day
Jenner Dye
Materion Milwaukee
Kata Journey
Late 2014-2016

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Materion Milwaukee
Inorganic Chemical Manufacturer
Offer 2,000+ Chemicals
We handle 70% of the periodic table every day!
Why Kata?
■ Stumbled Upon Kata
■ Struggled with Common CI Issues:
▪Limited Engagement
▪Long, Drawn-Out Projects
▪Chasing Savings
▪Slow/Declining Growth
How We Started
■ Operations Management Group
▪Toyota Kata book club
▪Just try Kata & learn as we go
How We Started
■ Picked Urgent Business Need
■ Established Process Level Target Conditions
■ Added to MDI agenda (Managing for Daily Improvement)
■ Began PDCA & Coaching
…then broadened to other Value Streams

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Gains
Cultural Results
▪Floor level engagement
▪Trying, failing, and learning
▪Daily improvement discussion
Gains
Business Results
▪Widespread Improvements
▪Captured New Business
▪Also Improved Several
Legacy Value Streams
What We Learned
■ No roll-out plan is good
■ No roll-out plan is bad
■ Practice vs. training/explaining
■ Using a “challenge” is helpful
■ Process Analysis is important for shifting mindsets
Next Steps
■ Get Current Ops Management Team Educated
■ Coaching, Coaching, Coaching
■ Process Analysis
Continue to…
KATA our KATA

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Discussion / Q&A
Lunch – Networking
▪ Lunch is outside the room in the hallway – Please help yourself
▪ Please return back to the room at 1:00pm to being Kata in the
Classroom
Kata in the Classroom Exercise
KATA IN THE CLASSROOM
EXERCISE
v5.5
www.katatogrow.com

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Kata in the Classroom - Introduction
• Student teams follow the
Improvement Kata pattern to
establish a goal and then experiment
toward it from round to round.
• Helps teach universal STEM skills for
achieving challenging goals along
uncharted paths:
– Scientific & Creative Thinking
– Collaboration
– Communication
www.katatogrow.com
• 50-minute exercise to introduce a practical pattern of scientific thinking in an
engaging way in schools
• Combines practical scientific pattern with techniques of deliberate practice,
to help make scientific thinking a teachable skill anyone can learn.
Kata in the Classroom - Objectives
1. Teacher has a positive experience with the simple, clear
four-step Improvement Kata pattern and uses same
pattern for other activities and projects during the
school year.
– This is where student practice and repetition of
scientific thinking comes from.
– Consider where else you might apply the scientific
four-step pattern of the Improvement Kata with
your students!
2. Students experience initial practicing of a scientific,
cross-curricular, "life skill" routine that can be used to
achieve challenging goals in a variety of situations.
www.katatogrow.com
Main objective is to teach awareness that ideas need to be tested.
What is a
KATA?
www.katatogrow.com
A is a routine you
practice, so it's pattern
becomes an automatic
habit that gives you
some new skills!
www.katatogrow.com

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Today we'll practice the
pattern of the
It's a scientific routine
for achieving tough
goals
www.katatogrow.com
Conduct
Experiments
to get there
Grasp the
Current
Condition
Establish
your Next
Target
Condition
Get the
Direction or
Challenge
1
2
3
4
THE FOUR STEPS OF
THE IMPROVEMENT KATA APPROACH
Poster
www.katatogrow.com
Conduct
Experiments
to get there
Grasp the
Current
Condition
Establish
your Next
Target
Condition
Get the
Direction or
Challenge
1
2
3
4
A FEW KEY POINTS
• You don't have to reach the overall challenge right away.
• The path is not predictable or straight.
• You experiment to get to the next target condition,
which makes it scientific.
www.katatogrow.com
For this exercise we'll build this 15-piece puzzle
several times, and experiment with ways
to do it faster
www.katatogrow.com

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Do the entire exercise
without the
puzzle frame
Go ahead and build the
puzzle one time!
Put the Frame Aside
• Take the puzzle out of the bag and study the picture.
• Remove the puzzle pieces from the frame.
• Put the frame back in the bag.
• Build the puzzle once, without timing it.
www.katatogrow.com
Choose a Team Name
Select a Data Recorder
 Write your team name
on the forms in the kit
Select a Timekeeper
 Use the stop watch on
your smartphone
THREE THINGS TO DO NEXT:
www.katatogrow.com
TODAY'S GROUND RULES
(1) "START Position" =
- Puzzle pieces shuffled in random order
- Pieces face down in one stack
- Hands flat on the table
- No talking, you're ready to go
(2) All Teams Start Together
a. Instructor calls "START"
b. Build the puzzle (talking allowed)
c. Note the elapsed time on your form
(3) Don't Write on the Puzzle
www.katatogrow.com
LET'S ESTABLISH A
BASELINE TIME FOR YOUR TEAM
Record your
times here
Use this
form
www.katatogrow.com

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Now let's do
the four steps of
the Improvement Kata
www.katatogrow.com
Conduct
Experiments
to get there
Grasp the
Current
Condition
Establish
your Next
Target
Condition
Get the
Direction or
Challenge
1
Step 1:
UNDERSTAND THE CHALLENGE
15
SECONDS
www.katatogrow.com
Key Points About:
UNDERSTANDING THE CHALLENGE
• We often face challenges in life.
No need to worry, because you
don't need to get all the way
there right away!
• A challenge often even gives us
a useful sense of direction.
www.katatogrow.com
Conduct
Experiments
to get there
Grasp the
Current
Condition
Establish
your Next
Target
Condition
Get the
Direction or
Challenge
Step 2:
GRASP THE CURRENT CONDITION
2
What was your
team's last
baseline time?
www.katatogrow.com
15
SECONDS

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• It's important to understand where
you currently are, before you set
your next goal (target condition).
• Don't pull goals randomly out of the
air. A team should feel like its goals
are meaningful.
Key Points About:
GRASPING THE CURRENT CONDITION
www.katatogrow.com
Conduct
Experiments
to get there
Grasp the
Current
Condition
Establish
your Next
Target
Condition
Get the
Direction or
Challenge
Step 3:
ESTABLISH YOUR NEXT
TARGET CONDITION
3
www.katatogrow.com
15
SECONDS
• Break a big challenge down into
smaller goals.
• Set an easier and closer goal
that's on the way to your
challenge. When you get there
you can set the next goal.
Key Points About:
ESTABLISHING YOUR NEXT
TARGET CONDITION
www.katatogrow.com
What puzzle build time does your team want
to reach by the end of today's class?
Conduct
Experiments
to get there
Grasp the
Current
Condition
Establish
your Next
Target
Condition
Get the
Direction or
Challenge
LET'S DEFINE YOUR TEAM'S
NEXT TARGET CONDITION
www.katatogrow.com
We can do five (5) rounds of experimenting today
15
SECONDS

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www.katatogrow.com
LET'S ASK EACH TEAM
www.katatogrow.com
DRAW YOUR TARGET CONDITION LINE
ON THE 'EXPERIMENTING' FORM
TC
www.katatogrow.com
Conduct
Experiments
to get there
Grasp the
Current
Condition
Establish
your Next
Target
Condition
Get the
Direction or
Challenge
Step 4:
CONDUCT EXPERIMENTS
TO GET THERE
4
www.katatogrow.com
15
SECONDS

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• You never know in advance exactly
how you will achieve a goal or target
condition.
• We need to test the ideas we have.
A good way to reach a goal is to
experiment rapidly. Try something,
see what happens, and then adjust
based on what you learn.
• To learn from an experiment you
should write down what you expect
and what actually happens, so you
can compare those two things.
Key Points About:
EXPERIMENTING TO GET THERE
www.katatogrow.com
HOW WE'LL EXPERIMENT
3 Minutes per Round
Instructor calls "START"
Build the puzzle
Note the elapsed time on your form
Based on what happened, discuss what
you plan to do next
Write ideas you want to test onto the form
www.katatogrow.com
(Before)
Write down the
next ideas you
want to test
(After)
Write in how
much the time
changed
compared to
the last round
(After)
Mark the
elapsed
time
THE EXPERIMENTING FORM
What to record in each round
www.katatogrow.com
PLEASE PLAN YOUR FIRST EXPERIMENT
Write the ideas you want to test next
on your 'Experimenting' form
Write down
the ideas you
want to test
www.katatogrow.com

Recommended for you

www.katatogrow.com
AFTER EACH EXPERIMENT
WE'LL REFLECT
After each round we'll ask one team
this set of Reflection Questions
www.katatogrow.com
GET READY FOR ROUND 1
3 Minutes per Round
Instructor calls "START"
Build the puzzle
Note the elapsed time on your form
Discuss what you plan to do next
Write ideas you want to test onto the form
----------
Time's up... Ask the Reflection Questions
Get into START Position (timekeeper raise hand)
www.katatogrow.com
www.katatogrow.com

Recommended for you

GET READY FOR ROUND 2
3 Minutes per Round
Instructor calls "START"
Build the puzzle
Note the elapsed time on your form
Discuss what you plan to do next
Write ideas you want to test onto the form
----------
Time's up... Ask the Reflection Questions
Get into START Position (timekeeper raise hand)
www.katatogrow.com
www.katatogrow.com
GET READY FOR ROUND 3
3 Minutes per Round
Instructor calls "START"
Build the puzzle
Note the elapsed time on your form
Discuss what you plan to do next
Write ideas you want to test onto the form
----------
Time's up... Ask the Reflection Questions
Get into START Position (timekeeper raise hand)
www.katatogrow.com
www.katatogrow.com

Recommended for you

GET READY FOR ROUND 4
3 Minutes per Round
Instructor calls "START"
Build the puzzle
Note the elapsed time on your form
Discuss what you plan to do next
Write ideas you want to test onto the form
----------
Time's up... Ask the Reflection Questions
Get into START Position (timekeeper raise hand)
www.katatogrow.com
www.katatogrow.com
GET READY FOR ROUND 5
3 Minutes per Round
Instructor calls "START"
Build the puzzle
Note the elapsed time on your form
Discuss what you plan to do next
Write ideas you want to test onto the form
----------
Time's up... Ask the Reflection Questions
Get into START Position (timekeeper raise hand)
www.katatogrow.com
www.katatogrow.com

Recommended for you

What are the four steps
of the Improvement Kata
approach?
Where else can we use
the four-step pattern
of
the Improvement Kata?
www.katatogrow.com
What’s Next?
• Run Kata in the Classroom on an In-service
day for teachers
• Think how you might deploy within a
school system as part of STEM
– Think of KiC deployment as a kata itself
– Rapid low cost trials
– Share learning and develop teacher /
student capacity
www.katatogrow.com
For others
• This is a quick way to introduce kata into a company setting
• There are other simulations that also can be used (both with or without the puzzle)
For School Systems:
Run a Kata in the Classroom Exercise
• Instructions are a “starter kata”
• Steps and underlying principles of the Improvement Kata are
broadly applicable.
• First run the exercise as designed (to get the thinking pattern
behind it) then adapt and use to suit your situation and purpose.
www.katatogrow.com
KiC Community
• Share your experiences with other teachers; send email to kata.classroom@gmail.com with:
• Photographs of your running of the KiC exercise.
• What you learn from conducting the KiC exercise, including suggestions for improving it.
• In what ways you adjust the exercise to meet your needs.
• Examples of how you apply the 4-step pattern of the Improvement Kata to other student
assignments, projects, etc.
Creative Commons Copyright
The Kata in the Classroom (KiC) materials are licensed under a Creative Commons Attribution-
NonCommercial-ShareAlike license. You are free to copy, use, remix, transform, build upon and
redistribute them as long as you note the source as katatogrow.com. However, these materials
may not be used for sale in any form. Use them, adapt them, share them.
KiC materials are free to download at www.katatogrow.com
A REFERENCE CARD
on the back of your Reflection Card
www.katatogrow.com

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Mark Niemi
KATA – Learning at All
Levels
Mark Niemi
Sr. Director of Operations
TIDI Products, LLC
Opportunity to Learn
Ariens Co. Auburn, NE

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Results
Results
▪ Non-Acute Care Market leader in infection
prevention products
▪ #1 market share in core “paper” offering for both
physician and dental offices
▪ Growth Focus on acute care consumable and
durables products
▪ Large, established customer base
▪ 3,000+ customers with 22-year tenure for top 10
customers
▪ Lean Manufacturing
▪ Continuous Improvement culture
“Supporting Caregivers and
Preventing Infections”
Facility Overview
Facility Year
Established
Employees Capabilities
Neenah, WI 1985 260
Non Acute Care Consumables
TIDI Paper and Tissue based products,
Clean Room, Eyewear, Custom Barriers
and Securement
Fenton, MI 2001 122
Acute Care Durables
Patient Positioning and Zero-Gravity
Flint, MI 2013 17 Clean Room and Distribution Center
Changshu,
China
2006 215 Acute Care Consumables
C-Armor and Large Equipment Barriers

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Non-Acute Care Consumables
▪ Grip-Lok® Securement
▪ Suite of patented catheter and line securement adhesive products
▪ Technology is used for holding tubes and catheters in place to
prevent infections and needle stick for practitioners
▪ End markets include Alternate Site and dialysis
Acute Care Durables
▪ Zero GravityTM System
▪ Suspended radiation protection system
▪ Replaces traditional heavy lead apparel, eliminating body strain
inherent to traditional methods
Acute Care Consumables
▪ C-Armor® Drape
▪ Expandable and collapsible sterile draping pouch.
▪ Reduces infection risk and complies with strict AORN standards
▪ Focused on OR end market
TIDI MANAGEMENT SYSTEM
2017

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Lean Management System
Easy to say, hard to do
▪ Long term goals
▪ Create a plan
▪ Measure the plan
▪ Review the plan
▪ Use the scientific method
▪ So… just get started!
▪ Learn and improve as you go
TIDI Management System Model
What problem are we trying to solve?
Achieve our long-term goals:
Grow EBITDA to $XXM (non-acquisition) Grow Sales $XXXM (non-acquisition)
Grow Gross Margin X% annually Grow EBITDA $XXM thru Acquisition
Commitment to Continuous Improvement
Values & Principles
Create Alignment & Constancy of Purpose
Process Improvement
What are we trying to improve?
Strategy Deployment 2017 Plans
Master A3’s
Focus A3’s
Supporting A3’s
Capability Development
How are we building leadership
capability & capacity?
Leadership assessment & plan
A3 Thinking & Coaching
Problem Solving (PDCA)
Daily Improvement (Kata)
Project Management
Rapid Improvement Events
Value Stream Mapping
Lean Management System
• Leaders Standard Work
• Visual Management
• Regular Accountability
& Support Meetings
• Leadership Discipline
Lean Management
System
IMPROVEMENT
MOUNTAIN
Lean Management System Definition
The leadership behavior that provides the glue to ensure
strategy deployment & capability development are operating
as intended (meeting the long term goals) and is continually
improving
Principles of a good Lean Management System
▪ Focused and connected to long term goals
▪ Drives continuous improvement
▪ A learning by doing process
▪ Utilizes the scientific method

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Lean Management System Components
1. Leader Standard Work
2. Visual Controls
3. Regular Accountability & Support Meetings
4. Leadership Discipline
Leader Standard Work Definition
Provides a structure and routine that shifts leaders from a sole
focus on results to a dual focus on process plus results
▪ The “paper” (documented Leader Standard Work)
describes the routine
▪ A list of normal actions that must be done to sustain the
TIDI Management System
▪ Typically includes regular meetings, audits, and reviews
▪ Focused on the process
▪ Connects the leader to visual controls & A3 plans
Leader Standard Work Example
▪ Bold items are the Lean Management System elements that support your A3 actions
and goals
▪ Non-bolded items are flexible and available for each individual to help them manage
their day/week/month
Author Mark Niemi
Last Revised 10/17/2016
What Responsibility When Frequency Details
Cross-functional Huddle Own, Delegate 8:30 AM Daily Use agenda posted at visual control board
Weekly Operations Meeting Participate Scheduled Weekly Enter update into OneNote before meeting
Operations Leadership Meeting Own, Lead Scheduled Weekly 3 weeks per month, review scorecard & actions + team development. 1 week per month, review financials
Strategy Deployment Review Participate Scheduled Monthly Update bowling chart before the meeting
1 on 1 meetings with each member of leadership team Own, Lead Scheduled Monthly Review top 3 things, lessons learned, next steps, personal development plan, & how can I help?
Strategic Planning Event Participate October Annually As part of COO / VP team
Strategic Planning Event Own, Lead November Annually Create plan for Neenah using startegy A3 process
Value Stream Mapping Event Own, Delegate, Participate November Annually Create RCI plan for Neenah using value stream mapping process
Kaizen Report Out Meetings Participate Scheduled On demand
Review email for urgent & important issues Own Morning Daily Follow-up with appropriate leaders
Review Neenah scorecard Own Before huddle Daily Look for key gaps to be disussed before Cross-functional Huddle meeing
End of first shift hand-off meeting Own, Delegate, Participate 1:45 PM Daily Attend occasionally to ensure discipline to the process
Update Neenah scorecard Own 1st TIDI day Monthly Create scorecard for new month. Delegate after established - January 2017?
Safety meetings Own, Delegate, Participate Scheduled Monthly Attend as team member. Ensure discipline to the process and tangible results.
Continuous Improvement Steering Committee Participate Scheduled Monthly
Create budget Participate September Annually
Neenah Director of Operations Standard
Work
Blue background with BOLD FONT indicates action critical to achieving Strategy Deployment goals
Lean Management System Components
▪ Leader Standard Work
▪ Visual Management
▪ Regular Accountability & Support Meetings
▪ Leadership Discipline

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Visual Management Definition
Something anyone can go to and clearly learn the status of
the process they are reviewing. Allows you to see normal
from abnormal and trends. Must be connected to the goals on
your A3.
▪ This can be a bowling chart, graphs, dashboard, or
management visual boards
▪ Can include problem solving tracking, lessons learned,
obstacles, follow up, etc.
▪ Leader standard work should direct you to the visual
controls
Examples
Metric Owner Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Plan(Mo.) $17,654,760 $14,798,504 $14,464,257 $17,853,193 $13,961,185 $14,152,891 $17,518,746 $15,059,050 $15,195,122 $17,544,327 $14,384,998 $14,733,372
Actual(Mo.) $16,643,910 $13,106,354 $13,680,407 $18,569,270 $14,133,515 $14,590,516 $16,622,101 $14,414,973 $14,122,572 $18,334,559
Plan(YTD) $17,654,760 $32,453,264 $46,917,521 $64,770,714 $78,731,899 $92,884,789 $110,403,536 $125,462,586 $140,657,707 $158,202,034 $172,587,032 $187,320,403
Actual(YTD) $16,643,910 $29,750,264 $43,430,671 $61,999,941 $76,133,456 $90,723,972 $107,346,073 $121,761,046 $135,883,618 $154,218,177
Plan(Mo.) $3,325,443 $2,980,946 $2,923,229 $3,591,691 $3,135,207 $3,062,321 $3,507,319 $3,303,069 $3,271,561 $3,607,855 $3,427,828 $3,461,319
Actual(Mo.) $3,478,885 $2,689,168 $2,768,840 $3,683,290 $3,081,465 $3,314,273 $3,714,276 $2,996,741 $3,107,359 $4,128,306
Plan(YTD) $3,325,443 $6,306,388 $9,229,617 $12,821,308 $15,956,516 $19,018,836 $22,526,156 $25,829,225 $29,100,786 $32,708,641 $36,136,470 $39,597,788
Actual(YTD) $3,478,885 $6,168,053 $8,936,894 $12,620,183 $15,701,649 $19,015,921 $22,730,198 $25,726,939 $28,834,298 $32,962,605
Plan(Mo.) $3,445,111 $2,746,803 $2,923,937 $3,424,362 $2,589,752 $2,719,858 $3,266,582 $2,656,317 $2,846,420 $3,022,957 $2,746,777 $3,061,919
Actual(Mo.) $2,833,959 $2,588,090 $2,338,172 $3,307,198 $2,522,085 $2,748,578 $3,049,141 $2,764,095 $2,639,076 $3,740,212
Plan(YTD) $3,445,111 $6,191,914 $9,115,851 $12,540,212 $15,129,964 $17,849,822 $21,116,404 $23,772,721 $26,619,141 $29,642,098 $32,388,875 $35,450,793
Actual(YTD) $2,833,959 $5,422,049 $7,760,221 $11,067,419 $13,589,504 $16,338,082 $19,387,223 $22,151,318 $24,790,394 $28,530,605
Plan(Mo.) $10,980,219 $9,150,182 $8,692,673 $10,932,781 $8,308,913 $8,444,458 $10,839,465 $9,156,966 $9,156,966 $11,008,896 $8,282,343 $8,282,343
Actual(Mo.) $10,324,179 $7,803,333 $8,486,026 $11,639,305 $8,532,937 $8,519,807 $9,857,654 $8,634,732 $8,366,207 $10,351,172
Plan(YTD) $10,980,219 $20,130,401 $28,823,074 $39,755,854 $48,064,768 $56,509,226 $67,348,691 $76,505,657 $85,662,623 $96,671,519 $104,953,863 $113,236,206
Actual(YTD) $10,324,179 $18,127,512 $26,613,537 $38,252,842 $46,785,780 $55,305,586 $65,163,240 $73,797,972 $82,164,179 $92,515,351
Plan(Mo.) $3,573,368 $3,013,573 $2,779,858 $3,610,953 $2,607,009 $2,710,789 $3,224,443 $2,952,354 $2,963,442 $3,230,211 $2,761,133 $2,963,881
Actual(Mo.) $3,619,654 $2,886,625 $2,452,094 $4,157,935 $2,836,655 $3,363,658 $3,948,887 $3,433,387 $3,328,454 $4,568,095
Plan(YTD) $3,573,368 $6,586,941 $9,366,799 $12,977,753 $15,584,762 $18,295,551 $21,519,994 $24,472,348 $27,435,790 $30,666,001 $33,427,135 $36,391,015
Actual(YTD) $3,619,654 $6,506,279 $8,958,373 $13,116,308 $15,952,963 $19,316,621 $23,265,508 $26,698,895 $30,027,349 $34,595,444
Plan(Mo.) 43.3% 43.4% 43.8% 43.6% 43.4% 43.6% 42.4% 43.1% 43.0% 42.6% 43.4% 44.0%
Actual(Mo.) 42.8% 46.0% 42.0% 43.6% 43.1% 45.7% 45.7% 46.9% 46.3% 47.9%
Month+/- -0.5% 2.6% -1.8% 0.0% -0.3% 2.0% 3.3% 3.7% 3.3% 5.3%
Plan(YTD) 43.3% 43.3% 43.5% 43.5% 43.5% 43.5% 43.3% 43.3% 43.3% 43.2% 43.2% 43.3%
Actual(YTD) 42.8% 44.3% 43.6% 43.6% 43.5% 44.8% 44.1% 44.4% 44.6% 45.0%
Gross Sales Commercial
Gross Sales -
Acute Care
Consumables
Gross Margin %
Gross Sales -
Acute Care
Durables
Management
EBITDA
Mike Duski
Mike Czop
Jim Rubright
Jeff Hebbard
Gross Sales - Non-
Acute Care
Consumables
Mike Duski
Lean Management System Components
▪ Leader Standard Work
▪ Visual Controls
▪ Regular Accountability & Support Meetings
▪ Leadership Discipline
Regular Accountability &
Support Meeting Definition
Regularly scheduled meetings with your team to review the
process and results
▪ Meeting have standard agenda & questions
▪ Holds leader and team accountable to the process
▪ Discuss current condition, target condition and gaps
▪ Coach & support the owner

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Midwest Kata Practitioners Day
Accountability & Support Meetings
(back of leader standard work form)
Author Mark Niemi
Last Revised 10/17/2016
What Responsibility When Frequency Details
Cross-functional Huddle Own, Delegate 8:30 AM Daily Use agenda posted at visual control board
Weekly Operations Meeting Participate Scheduled Weekly Enter update into OneNote before meeting
Operations Leadership Meeting Own, Lead Scheduled Weekly 3 weeks per month, review scorecard & actions + team development. 1 week per month, review financials
Strategy Deployment Review Participate Scheduled Monthly Update bowling chart before the meeting
1 on 1 meetings with each member of leadership team Own, Lead Scheduled Monthly Review top 3 things, lessons learned, next steps, personal development plan, & how can I help?
Strategic Planning Event Participate October Annually As part of COO / VP team
Strategic Planning Event Own, Lead November Annually Create plan for Neenah using startegy A3 process
Value Stream Mapping Event Own, Delegate, Participate November Annually Create RCI plan for Neenah using value stream mapping process
Kaizen Report Out Meetings Participate Scheduled On demand
Review email for urgent & important issues Own Morning Daily Follow-up with appropriate leaders
Review Neenah scorecard Own Before huddle Daily Look for key gaps to be disussed before Cross-functional Huddle meeing
End of first shift hand-off meeting Own, Delegate, Participate 1:45 PM Daily Attend occasionally to ensure discipline to the process
Update Neenah scorecard Own 1st TIDI day Monthly Create scorecard for new month. Delegate after established - January 2017?
Safety meetings Own, Delegate, Participate Scheduled Monthly Attend as team member. Ensure discipline to the process and tangible results.
Continuous Improvement Steering Committee Participate Scheduled Monthly
Create budget Participate September Annually
Neenah Director of Operations Standard
Work
Blue background with BOLD FONT indicates action critical to achieving Strategy Deployment goals
Standard Questions Agenda for Weekly Operations Meeting
What is your target condition? Have notes from rpevious meeting for reference to ensure continuity
What is the actual condition now? Assign a note taker to record what, who, when, and how for each action discussed
What did you do as your last step? Review time allocated for this meeting (finish on time!)
What did you expect? Review Neenah Scorecard
What actually happened? Safety - ask the standard questions and record learning and next steps
What did you learn? Quality - ask the standard questions and record learning and next steps
What obstacles are keeping you from reaching the target condition? Delivery / Plan attainment - ask the standard questions and record learning and next steps
Which one are you addressing now? Productivity - ask the standard questions and record learning and next steps
What is you next step? People / Turnover - ask the standard questions andrecord learning and next steps
What do you expect to happen? Review top 3 things for each team member with progress update
How soon can we see what we have learned by taking that next step? Review all action items for agreement that we are working on the most important
Adjust if necessary to ensure maximum progress
Ensure each action item has what, who, when, and how agreed upon and recorded for next meeting
Agenda for Monthly One-on-One Meetings
Focus – What are your Top 3 things?
Describe in a single sentence the intended successful outcome, in other words what
would need to happen to check this project off as done?
Write down the very next physical action required to move the situation forward
Review A3’s
Review departmental expense
Review scorecard(s)
Discuss team development
Discuss personal development – including 2 lean leader behaviors
Open discussion
Agenda for Cross-Functional Huddle
Posted in Huddle Board area
Lean Management System Components
▪ Leader Standard Work
▪ Visual Controls
▪ Regular Accountability & Support Meetings
▪ Leadership Discipline
Leadership Discipline Definition
Finding the courage and resolve to learn, understand, and hold
yourself and your team accountable to the lean management system
▪ Live and Learn the Lean Leadership Fundamental Behaviors
▪ Willingness … Reflection
▪ Humility … Go See, Listen, & Learn
▪ Curiosity … Ask Questions, Effective Listening, A3 Thinking
▪ Perseverance … Partner, Buddy System, Coach
▪ Self-Discipline … Leader Standard work
▪ Backsliding starts when something else becomes more important
or we don’t have the discipline to adhere to the system

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How does this all fit?
▪ The key focus is strategy deployment
▪ Recognize there is other work that must be done
▪ Suggest only one leader standard work document
▪ Use bold for Strategy Deployment actions and non-bold for others
▪ Limit accountability & support meetings to what is absolutely
necessary
▪ For example – direct report one on ones can cover both strategy
deployment, daily continuous improvement and big rocks (top three
priorities)
Strategy
Deployment
LMS
Daily
Continuous
Improvement
Big Rocks True North
Title: What change or improvement are you talking about? Owner/Date
1.Background: what are you talking about and why?
What is the purpose, business reason for choosing this issue?
What specific performance measure needs to be improved?
What is the strategic, operational, historical, or organizational context of the situation?
2. Current Conditions: Where do things stand now?
What is the problem or need – the gap in performance?
What is happening now versus what you want or needs to be happening?
Have you been to the Gemba?
What facts or data indicate there is a problem?
What specific conditions indicate that you have a problem or need?
Where and how much? Can you break the problem into smaller pieces?
Show facts and processes visually using charts, graphs, maps, etc.
3. Goals: What specific outcome is required?
4. Analysis: Why does the problem or need exist?
5. Recommendations: What do you propose and why?
6. Plan: How will you implement? (4W’s, 1H)
7. Follow-up: How will you ensure ongoing PDCA?
What specific improvement (S) in performance you need to achieve?
Show visually how much, by when, and with what impact.
Don't state a countermeasure as a goal!
What do the specifics of the issues in work processes (location, patterns, trends, factors) indicate about why
the performance gap or need exists?
What conditions or occurrences are preventing you from achieving the goals?
Why do they exist? What is (are) their cause (S)?
Use the simplest problem analysis tool that will suffice to show cause and effect down to the root
cause. From 5 wise to 7 Q C tools (fish bones, analysis trees, Pareto charts, to more sophisticated SPC,
6 Sigma, and other tools as needed.
Test the cause-and-effect logic by asking "why?" Downward and starting "therefore" upward.
What are the options for addressing the gaps in improving performance the current situation?
Always start with two or three alternatives to evaluate.
How do they compare in effectiveness, feasibility, and potential disruption?
What are their relative costs and benefits?
Which do you recommend and why?
Show your proposed actions will address the specific causes of the gaps strangely identified in your analysis. The link
should be clear and explicit!
What will be the main actions and outcomes in the implementation process and in what sequence?
What support and resources will be required?
Who will be responsible for what, when, and how much?
How will you measure effectiveness?
When will progress be reviewed and by whom?
Use a Gantt chart (or similar diagram) to display actions, steps, outcomes, timeliness, and roles.
How and when will you know if plans have been followed and actions have had the impact planned and needed?
How you know if you met your targets?
How will you know if you reduced the gap in performance?
What related issues or unintended consequences do you anticipate?
What contingencies can you anticipate?
What processes will you use to enable, sure, and sustained success?
How will you share your learnings with other areas?
Strategy A3(s)
Created Annually
Neenah Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
SAFETY 2015 Act 0 2 2 0 0 1 0 1 2 2 0 2
RECORDABLES 2016 Act 0 1 0 2 0 0 4 5 1 0
2016 Plan 0 0 0 0 0 0 0 0 0 0 0 0
Performance 0 1 0 2 0 0 4 5 1 0
Note: Ergonomicassessmentwas done in September, awaitingresults forfurtherplanning.
QUALITY 2015Act 0.50% 0.55% 0.62% 0.61% 0.60% 0.57% 0.78% 0.78% 0.58% 0.73% 0.73% 0.62%
COST OF QUALITY 2016Act 0.76% 0.52% 0.52% 0.50% 0.66% 0.51% 0.73% 0.61% 0.60%
2016Plan 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50%
Performance 152.0% 104.0% 104.0% 100.0% 132.0% 102.0% 146.0% 122.0% 120.0%
Note: Shortage on shipmentfor3500on nose clip, investigatingshortage.
PRODUCTIVITY 2015Act NA NA NA NA NA NA NA NA NA NA NA NA
STD / ACT LABOR 2016Act 92.0% 102.0% 98.8% 98.5% 104.0% 99.8% 93.0% 96.6% 99.9%
2016Plan 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
Performance 92.0% 102.0% 98.8% 98.5% 104.0% 99.8% 93.0% 96.6% 99.9%
Note:
DELIVERY 2015Act 79.8% 96.7% 90.6% 92.3% 94.0% 96.3% 94.1% 96.9% 86.9% 98.3% 97.1% 92.6%
CUSTOMER LINE FILL 2016Act 98.9% 98.8% 93.9% 98.5% 99.4% 99.3% 94.9% 93.8% 93%
2016Plan 97% 97% 97% 97% 97% 97% 97% 97% 97% 97% 97% 97%
Performance 102.0% 101.9% 96.8% 101.5% 102.5% 102.4% 97.8% 96.7% 96.0%
Note:Base stock items and large customers performance continues tobe atstandard. Continue tostruggle with staffingin shippingtocoverdaily spikes.
INVENTORY 2015 Act 49 56 50 51 55 54 53 54 60 55 54 55
DIOH 2016 Act 64 66 63 57 58 60 68 69 70
2016 Plan 62 60 60 59 60 59 57 53 53 53 56 56
Performance 102.4% 110.0% 105.0% 96.6% 96.7% 101.7% 119.3% 130.2% 132.1%
TIDI Monthly Operations KPI's by Facility
Author Mark Niemi
Last Revised 10/17/2016
What Responsibility When Frequency Details
Cross-functional Huddle Own, Delegate 8:30 AM Daily Use agenda posted at visual control board
Weekly Operations Meeting Participate Scheduled Weekly Enter update into OneNote before meeting
Operations Leadership Meeting Own, Lead Scheduled Weekly 3 weeks per month, review scorecard & actions + team development. 1 week per month, review financials
Strategy Deployment Review Participate Scheduled Monthly Update bowling chart before the meeting
1 on 1 meetings with each member of leadership team Own, Lead Scheduled Monthly Review top 3 things, lessons learned, next steps, personal development plan, & how can I help?
Strategic Planning Event Participate October Annually As part of COO / VP team
Strategic Planning Event Own, Lead November Annually Create plan for Neenah using startegy A3 process
Value Stream Mapping Event Own, Delegate, Participate November Annually Create RCI plan for Neenah using value stream mapping process
Kaizen Report Out Meetings Participate Scheduled On demand
Review email for urgent & important issues Own Morning Daily Follow-up with appropriate leaders
Review Neenah scorecard Own Before huddle Daily Look for key gaps to be disussed before Cross-functional Huddle meeing
End of first shift hand-off meeting Own, Delegate, Participate 1:45 PM Daily Attend occasionally to ensure discipline to the process
Update Neenah scorecard Own 1st TIDI day Monthly Create scorecard for new month. Delegate after established - January 2017?
Safety meetings Own, Delegate, Participate Scheduled Monthly Attend as team member. Ensure discipline to the process and tangible results.
Continuous Improvement Steering Committee Participate Scheduled Monthly
Create budget Participate September Annually
Neenah Director of Operations Standard
Work
Blue background with BOLD FONT indicates action critical to achieving Strategy Deployment goals
Standard Questions Agenda for Weekly Operations Meeting
What is your target condition? Have notes from rpevious meeting for reference to ensure continuity
What is the actual condition now? Assign a note taker to record what, who, when, and how for each action discussed
What did you do as your last step? Review time allocated for this meeting (finish on time!)
What did you expect? Review Neenah Scorecard
What actually happened? Safety - ask the standard questions and record learning and next steps
What did you learn? Quality - ask the standard questions and record learning and next steps
What obstacles are keeping you from reaching the target condition? Delivery / Plan attainment - ask the standard questions and record learning and next steps
Which one are you addressing now? Productivity - ask the standard questions and record learning and next steps
What is you next step? People / Turnover - ask the standard questions andrecord learning and next steps
What do you expect to happen? Review top 3 things for each team member with progress update
How soon can we see what we have learned by taking that next step? Review all action items for agreement that we are working on the most important
Adjust if necessary to ensure maximum progress
Ensure each action item has what, who, when, and how agreed upon and recorded for next meeting
Agenda for Monthly One-on-One Meetings
Focus – What are your Top 3 things?
Describe in a single sentence the intended successful outcome, in other words what
would need to happen to check this project off as done?
Write down the very next physical action required to move the situation forward
Review A3’s
Review departmental expense
Review scorecard(s)
Discuss team development
Discuss personal development – including 2 lean leader behaviors
Open discussion
Agenda for Cross-Functional Huddle
Posted in Huddle Board area
Focus: TIDI Operations
Task
No. Task Owner
Target
Date J F M A M J J A S O N D Status Next Step
1 BUILD A GREAT TEAM
1.1 Assess team & structure - Neenah, Fenton, China Jeff H. 6/1/16 - - - - > X In proces - N solid, F needs work, C solid but thin On board EB, coach JZ, leverage Neenah
1.2 Hire Operations Leader for Fenton Jeff H. 6/1/16 - - - - > X Complete
1.3 Complete team structure for Fenton Jeff H. 12/1/16 - - - - > X After Dir of Ops in place Work with EB, she needs some time to assess
1.4 Team development plans Jeff H. On going X X X X X X X X X X Started 1:1's - not mission critical right now
2 TIDI STRATEGY DEPLOYMENT
2.1 Top level X-Matrix completion Jeff H. / ELT 3/30/16 X Complete
2.1.1 6 Month Strategy Deployment Review (Kevin called this - add to std work for 2017) KM/ELT 6/15/16 X Complete
2.2 Deployment to organization - assist other departments on their deployment Jeff H. 3/30/16 X Complete Complete but opportunity for improvement
2.3 Monthly Strategy Deployment meeting Jeff H. / Mgmt On Going X X X X X X X X X X X X Meeting held with fully updated x-matrix
2.4 Achieve enterprise results ELT On Going X X X X X X X X X X X X
Sales off, EBITDA on target, Margin on target,
some WI RED
Countermeasures identified - need to track
2.5 Reflection on 2016 and create 2017 process Jeff H. / ELT 12/31/16 X
JH needs to take more ownership, take more
time, and show more discipline to process
3 BUILD A LEAN MANAGEMENT PROCESS FOR OPERATIONS
3.1 Create Operations 2016 Business Plan - A3 Jeff H. 3/30/16 X Complete Review in monthly 1:1's
3.2 Create Operations 2016 key metrics - Bowling Chart Jeff H. 3/30/16 X Complete Review in monthly 1:1's
3.3 Deploy operations A3 and create departmental business plans & metrics (visual controls) Jeff H. 3/30/16 X Discussions & drafts done Starting review in monthly 1:1's
3.4 Determine accountability meeting structure - team, huddles, 1:1's (PDCA) Jeff H. On going X X X X X X X X X
3.5 Create Leader Standard Work Jeff H. X
3.6 Discipline to the process Jeff H. On going X X X X X X X X X
4 FENTON OPERATIONS IMPROVEMENT
4.1 Pick core team - define the current state (brutal reality) Jeff H. 3/1/16 X Complete
4.2 Pick one to two measures Jeff H. 4/18/16 X Complete Needs follow up on status
4.3 P/Q analysis - pick areas to attack Jeff H. 3/30/16 X Complete
4.4 Value Stream Map Event Jeff H. 4/18/16 X Complete
4.5 Complete Value Stream Map Action Plan Jeff H. On going X X X X X X X X In process Matress cell behind, others on target
4.6 Implement Lean Management System in Fenton Jeff H. 4/30/16 X No progress - need leader in place first
5 TIDI CONTINUOUS IMPROVEMENT - BUSINESS SYSTEM
5.1 Reflection event Jeff H / LSC 4/1/16 X Complete
5.2 Create Continuous Improvement A3 Jeff H. 4/1/16 X Complete
5.3 Assess staffing and leadership needs and build the team Jeff H. 6/1/16 - > X Still examining opportunities and need
5.4 Lean leadership training program Jeff H 11/1/16 - - - - - > X
5.5 Kaizen event planning and approval - build more robust process connected to True North & results desired Jeff H 12/1/16 - - - - - - > X Some progress since reflection, still needs work
5.6 Enhance problems solving and usage Jeff H 12/1/16 - - - - - - > X
6 CHINA OPERATIONS IMPROVEMENT
6.1 Visit China facility - first assessment Jeff H 5/15/16 X Complete
6.2 Create 2016 action plan and metrics Jeff H 6/1/16 X KPI's in place and being reported
6.3 Implement Lean Management System Jeff H On going X X X X X X X
7 REDUCE COMPLEXITY - SIMPLIFY THE BUSINESS (Margin Master A3)
7.1 80/20 PLS event Neenah Jeff H. 4/1/16 X Started - gaining momentum Work the plan
7.2 80/20 PLS event Fenton Jeff H. 6/1/16 X Started Need to see and assess plan
7.3 80/20 PLS event China Jeff H. 11/1/16 X
7.4 Cost Reduction - Material, Labor, Expense, CI Jeff H. On going X X X X X X X X X X X
8 OTHER
8.1 Asiste in Create / Improve the Product Development process No current plan
8.2 My personal education in all business processes Jeff H. On-going X X X X X X X X X X X On-going, Gemba walks, 1:1's Tradeshow, customer visits
8.3 Assist / Co-Lead Margin A3 Jeff H. On-going X X X X X X X X X X Taken over full responsibility More time with leaders
Author: Jeff Hebbard
Revision #: 4
Date: 6/22/2016
FY2017 Action Plan
On Target
Behind Target
Trouble
Action Plan(s) – updated monthly
SD + DCI + Big Rocks Visual Controls – updated monthly
Leader Standard Work
Q&A
Nate Rife

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Kata at Bradley
Specialties GroupA division of Bradley Corporation
Nate Rife – BOS Manager
Josh Rauen – Manufacturing Supervisor
Germantown, WI
Accessories Plant
Previous Lean Deployment
• Focus on tools
• Kaizen “Events” using the tools (typically 5S or
VSM)
• Large action lists
• Difficult to sustain improvements
• Improvements not always tied to process
(therefore limited impact on plant level results)
Our Kata Approach: building on our
experience
• Tools are the same… 5S, line balancing, setup
reduction, etc.
• The difference is in the kata structure (IK and CK)
• Tools are only used to eliminate obstacles
preventing achievement of the next TPC.
• Not a “Management Fad”

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Kata on the Mirror Line
Pre-Kata Current Condition
People: 4/5 2, 3, 4, or 5
Flow: 1x1 (60 boxes) 1x1 (5 boxes)
Cadence: CT = 34s (4 EE’s) CT = 34s, 49s, 64s
Variance: 10s to 138s +/- 21s
Operator Engagement thru PDCA
▪ Operators recording their own data for
PDCA loops.
▪ Examples of exit cycle times for
playbook manning options and line
balancing
▪ Single Piece Flow (Wendy’s story)
PDCA loops: using the tools to
eliminate obstacles
Std Work
and
Playbook
Component
Kanban
Setup
Reduction
Line
Balance 5S
Mirror Line Results
• Output from approximately 300 mirrors/day to up to
450 mirrors/day
• OPR: from 45% to up to 63%
• Output scalable to meet customer demand (takt)
• Biggest benefit: Newfound capability in operator, re-
assigned to drive continuous improvement in other
areas.

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Not just the production process
• Inventory Accuracy and the put-away process
• Grab Bar escutcheon quality issue
• Ubar 3P activity
Current Future
People 4 2-4 (adjustable)
Flow 1 x 1 1 x 1
Cadence
CT = 20 Sec/pc
with one shift
(2016 demand of
1160 bars/day)
CT = 25 to 34
sec/pc with two
shifts.
(2019 demand of
1543 bars/day)
Variance OPR = 60-85% OPR = 70-85%
Ubar Line 3P
Grab Bar Escutcheon
Quality Problem
Key Learning's
• Partnering with someone who knows the kata approach
was a huge benefit!
• Smaller is better… we tend to set big TPC’s
• Smaller TPC’s promote quicker PDCA cycles and simple
solutions. Beware of waiting for the big solution (label
printer)
• Team creativity is priceless
• Plant-level challenge helps set good TPC’s
• Coaching is harder than we thought… we need a good
plan (kata the kata)
Kata the Kata
A3: Plant Challenge/Cascading
Dept Challenges
Map of Improvement
(StoryBoards)
People: Jeff H, Jeff B, Nate R, Josh R, Rick
S, Greg S, Jeff J
Flow: 2 Week TPC’s, On track to
Quarterly Dept Challenge
Cadence: Weekly
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1. Learn more about Toyota Kata
2. Try it!
3. Rinse and Repeat
Next Steps
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Website…
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hat_is_a_Kata.html
Learn more about Toyota Kata
Learn more about Toyota Kata
Read the book…

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Learn more about Toyota Kata
Attend the Conference…
katasummit.com
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Try it!!!
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Midwest Kata Practitioners Day

  • 1. Midwest Kata Practitioner Day January 5, 2017
  • 2. Safety Guidelines for Today • Emergency Exits • Bathrooms
  • 4. Reminders • Presentations will be available for download after today’s event • Hold all Q&A for the Discussion/Q&A sessions on the agenda • Be sure to network today!
  • 5. Why KPDs? KataCon 3 The 3rd Annual Kata Summit San Diego, California February 21-22, 2017 Brought to you by Are you ready for this? Calling all Improvement Kata / Coaching Kata practitioners, and those who would like to be! Whether you were part the first or second Summit or not, Improvement Kata and Coaching Kata users. The Summit emphasizes experiential learning so practitioners, trainers and consultants can integrate practice of the IK/CK routines into their teams and organizations. This conference goes beyond concepts by equipping attendees to train and practice at home. A supplementary accessible, compact, regional forum for sharing IK/CK activity Two passes will be given away at the end of today!
  • 6. KPD - Purpose • Learn more about Improvement Kata / Coaching Kata • Share experiences with making scientific thinking a practical skill that anyone can learn through practice. • See what Midwest organizations are doing and learning with IK/CK practice • Encourage Communities of Practice in the Midwest
  • 7. KPD - Desired Outcomes • You have a better understanding of the IK/CK approach to improvement, adaptation and innovation • You're thinking about scientific thinking • You're inspired to help develop scientific thinking in young people • Interest in a Community of Practice • Maybe we meet again
  • 8. 1) DIY • Not just copying • Practice the "Starter Kata," then evolve your own way Improvement Kata Spirit 2) You're Part of It • At the KPD – Pick up as much as you can • After the KPD – Practice, and share what you learn
  • 9. What’s Your IK/CK Experience Level? Newbie: Heard about Kata, want to learn more, not yet practicing Advanced Beginner: Practicing for 2 or less years Competent: Practicing for 2 – 4 years, Coaching Proficient: Practicing for > 4 years, Coaching and Teaching
  • 10. KPD Agenda Overview AM • Keynote • Overview of IK/CK • Q&A / Discussion • 20-Minute Break • 3 Practitioners • Q&A / Discussion PM • "Kata in the Classroom" Exercise • 20-Minute Break • 3 Practitioners • Q&A / Discussion • Next Steps LUNCH (60 min) Networking 9:00 - Start 12:00 - End 1:00 - Start 4:30 - End
  • 14. Kata Practitioner Day: Improvement and Coaching Kata Overview Mike Radtke January 5, 2017 New Roots Consulting, LLC 2016
  • 15. Behaviors Drive Outcomes An organization’s collection of practices and principles at any point in time is an outcome that springs from its members’ routines of thinking and behavior. Any organization’s competitiveness, ability to adapt , and culture arise from the routines and habits by which the people in the organization conduct themselves every day. It is an issue of human behavior. Mike Rother, Toyota Kata New Roots Consulting, LLC 2016
  • 16. Toyota Research – 2 Questions 1. What are the unseen managerial routines and thinking that lie behind Toyota’s success with continuous improvement and adaptation? 1. How can other companies develop similar routines and thinking in their organizations? New Roots Consulting, LLC 2016
  • 17. What does daily improvement look like today in your organization? New Roots Consulting, LLC 2016
  • 18. WHAT ARE KATA? They're practice routines. Kata are structured routines to practice deliberately, especially at the beginning, so their pattern becomes a habit and leaves you with new abilities. Kata are for learning fundamentals that you can build on. Kata are a way of transferring skills and developing shared abilities and mindset in a team or organization. “Let’s begin by practicing it this way for a while” Science + Kata = Problem Solving Skill Combining a scientific pattern with structured practice routines (Kata) develops effective problem solvers By Mike Rother
  • 19. The Routines of the Improvement Kata and Coaching Kata are Practiced to Develop Scientific Mindset WHAT KATA ARE FOR Beginners should follow Kata exactly; not deviating from them, so the Learner can internalize the patterns. But with increasing proficiency each Learner can start to (within limits) develop their own style. Likewise, over time each organization can evolve the Kata it began with to better suit and mesh with its culture. The original Kata evolve into organization-specific practice routines. Kata Practice To develop foundational skill and mindset By Mike Rother
  • 20. (1) FOLLOW: Start by repeating each practice routine without modification, so you can absorb its fundamental pattern. (2) DETACH: Once the basic patterns get habitual and you understand the 'why' behind them, you'll start to adapt them. HOW LONG DO YOU PRACTICE RELIGIOUSLY? (3) FLUENCY: At this stage your actions become natural. You can create your own approaches to fit different circumstances, while sticking to basic underlying principles. Real practice doesn't pass through these discrete stages, but they are a useful way to depict your progression By Mike Rother
  • 21. THE IMPROVEMENT KATA + THE COACHING KATA It’s a methodology for developing people to meet challenges By Mike Rother (Manager) Improvement Kata Coaching Kata Understand the Direction or Challenge Grasp the Current Condition Establish the Next Target Condition Experiment Toward the Target Condition ‘Executing’ Coaching Cycles ‘Planning’ Coaching Cycles Learner Coach
  • 22. THE IMPROVEMENT KATA + THE COACHING KATA It’s a methodology for developing people to meet challenges By Mike Rother (Manager) Improvement Kata Coaching Kata Understand the Direction or Challenge Grasp the Current Condition Establish the Next Target Condition Experiment Toward the Target Condition ‘Executing’ Coaching Cycles ‘Planning’ Coaching Cycles Learner Coach
  • 23. THE IMPROVEMENT KATA + THE COACHING KATA It’s a methodology for developing people to meet challenges By Mike Rother (Manager) Improvement Kata Coaching Kata Understand the Direction or Challenge Grasp the Current Condition Establish the Next Target Condition Experiment Toward the Target Condition ‘Executing’ Coaching Cycles ‘Planning’ Coaching Cycles Learner Coach
  • 25. CONNECTING STRATEGY & EXECUTION By Mike Rother 25 Vision Next Target Condition Current Condition Obstacles Challenge Execution Strategy Leaders establish the organizations strategic concept (the “rallying point” or overall direction) Managers develop people by coaching application practice of the Improvement Kata in the direction of the challenge The role of Challenge in an organization
  • 26. Value Stream Mapping 5 min. 65 min. 8 min. 55 min. 2 min. 536 min. 9 min. 15 min. 53 min. Pacemaker Loop Planning Loop New Roots Consulting, LLC 2016
  • 27. Grasping the Current Condition • Flow Mapping • Time Observations • Standard Work • Spaghetti Diagrams • Data Analysis • Going to See New Roots Consulting, LLC 2016
  • 28. By Mike Rother 28 ESTABLISHING TARGET CONDITIONS Experiments At the Current Knowledge Threshold Challenge Threshold of Knowledge Current Condition Next Target Condition (date)
  • 29. • Break a big challenge down into smaller goals. • Set an easier and closer goal that's on the way to your challenge. When you get there you can set the next goal. Key Points About: ESTABLISHING YOUR NEXT TARGET CONDITION By Mike Rother
  • 30. Setting Short Term Target Conditions • On the path to the overall Challenge • Timeframe – 1 weeks to 3 months • A condition – fast forward in time. What conditions do you want to bring into existence? (not a solution) • Developed initially by the learner (and team if appropriate), but ultimately determined through dialogue between the learner and coach New Roots Consulting, LLC 2016
  • 31. A CHALLENGE FOR THE COACH The Learner should practice in a Learning Zone, beyond their current knowledge and skill thresholds, yet also periodically get a feeling of progress. In other words, the Coach is responsible for the Learner's success. Apparent Certainty Learning new skills and habits requires an emotion of enthusiasm in the Learner By Mike Rother
  • 33. A3 /PDSA Thinking PLANADJUST STUDY DO New Roots Consulting, LLC 2016 Go and See
  • 34. THE IMPROVEMENT KATA + THE COACHING KATA It’s a methodology for developing people to meet challenges By Mike Rother (Manager) Improvement Kata Coaching Kata Understand the Direction or Challenge Grasp the Current Condition Establish the Next Target Condition Experiment Toward the Target Condition ‘Executing’ Coaching Cycles ‘Planning’ Coaching Cycles Learner Coach
  • 35. The Learner's Storyboard Start with this format By Mike Rother
  • 36. A Pattern for Daily Improvement • Identifying the Process • What conditions we’d like to exist within the process at a specific point in the future • Setting a date What are we trying to achieve? By when? 1 New Roots Consulting, LLC 2016
  • 37. A Pattern for Daily Improvement How are we currently performing today? (Visual) 2 • Outcome metrics • Process metrics • Track at least daily • Makes gap between current and target visible New Roots Consulting, LLC 2016
  • 38. A Pattern for Daily Improvement What Obstacles/Root causes are preventing you from reaching your target (1) and what one are you going to address next? 3 • What root causes exist today that need to be addressed? • What one obstacle do you plan on addressing? What led you your decision? New Roots Consulting, LLC 2016
  • 39. PDSA CYCLE RECORD New Roots Consulting, LLC 2016
  • 40. A Pattern for Daily Improvement What key problem were you last working on? What did you try? What did you think was going to happen? 4 • Planning your experiment • What root cause/obstacle are you addressing? • What experiment do you plan on performing in pursuit of addressing that obstacle? • What do you expect to happen? New Roots Consulting, LLC 2016
  • 41. A Pattern for Daily Improvement What actually happened? What did you learn? 5 • What changed within the process? (Look at the visual tracking of the current condition) • What other things were impacted? (Both for the positive and negative) • What was the impact to the social environment? • What did we learn by that experiment? New Roots Consulting, LLC 2016
  • 42. A Pattern for Daily Improvement • What is our current condition now in relation to our target condition? • What obstacles did we remove? • What new obstacles did we discover? New Roots Consulting, LLC 2016 What obstacle did we address? new obstacles did we uncover? What is our current performance now in relation to our target condition? 6
  • 43. A Pattern for Daily Improvement What key problem are you working on next? What are you going to try? What do you expect to happen? 7 • What will you experiment with to address that obstacle/root cause? How did you come to that decision? • What do you expect to happen? (Positive and negative) New Roots Consulting, LLC 2016
  • 44. A3 and Kata Background Current Condition Problem Statement: Goals/Targets Gap Analysis Countermeasures Follow Up Plan New Roots Consulting, LLC 2016
  • 45. SCIENTIFIC THINKING Scientific thinking is a routine of intentional coordination between what we think will happen (theory), what actually happens (evidence), and adjusting based on what we learn from the difference. What we expect to happen What actually happened Learning "Let'stryitandsee" By Mike Rother
  • 46. THE IMPROVEMENT KATA + THE COACHING KATA It’s a methodology for developing people to meet challenges By Mike Rother Improvement Kata (Manager) Coaching Kata Understand the Direction or Challenge Grasp the Current Condition Establish the Next Target Condition Experiment Toward the Target Condition ‘Executing’ Coaching Cycles ‘Planning’ Coaching Cycles Learner Coach
  • 47. THERE'S ALSO A COACHING KATA A way of coaching. Toyota's Master-Apprentice style teaching approach is like training in sports and music. Together the Improvement Kata and Coaching Kata make up a management approach Learner Coach (Manager) By Mike Rother
  • 48. Coaching is… As in sports and music, practicing should be done under periodic observation and guidance of an experienced coach. Without coaching we lose our way and don’t practice the right pattern, or practice ineffectively. Without coaching, a change in our mindset -- in our brain's wiring -- is unlikely to occur. Mike Rother
  • 50. Developing New Habits • By practicing a specific routine around ‘how’ you do daily improvement and coaching, it becomes a habit • Once you develop the habit, it can become a repeated pattern of how you address problems toward improving performance within your organization New Roots Consulting, LLC 2016
  • 51. Roles / Org Structure for Practicing Learner's Storyboard LearnerCoach (Manager) 2nd Coach Team Practices the Improvement Kata Practices the Coaching Kata Coaches the Coach By Mike Rother
  • 52. THE IMPROVEMENT KATA + THE COACHING KATA It’s a methodology for developing people to meet challenges By Mike Rother Improvement Kata (Manager) Coaching Kata Understand the Direction or Challenge Grasp the Current Condition Establish the Next Target Condition Experiment Toward the Target Condition ‘Executing’ Coaching Cycles ‘Planning’ Coaching Cycles Learner Coach
  • 54. William Boyd / Jeff Uitenbroek
  • 57. ABOUT SERIGRAPH Plastic printing, in-mold labeling & custom graphics company specializing in decorative, functional & brand solutions • Established: 1949 • Ownership: Private • Headquarters: West Bend, WI – USA • Employees: 750 • Plant Locations:West Bend, WI Querétaro, Mexico
  • 58. MARKETS • Appliance • Automotive • Medical • Power Sports / Outdoor Equipment • Consumer Products • Aerospace • Sporting Goods
  • 59. PRODUCT OFFERING • In-mold labeling • Decorative overlays • Decals & labels • Badges/nameplates
  • 60. CORE COMPETENCIES • Graphic Design • Color Matching/Lighting Development • Material Science • Prototyping • Printing • Forming • IML/IMD Molding • Cutting • Assembly • Finishing • Inspection • Testing/Validation • Vendor Managed Inventory (VMI)
  • 61. QUALITY MANUFACTURING • TS* 16949 certified • ISO 9001 certified • ISO 14001** certified • Lean/Six Sigma continuous improvement system • Fully equipped clean rooms • In-house, TS-certified test facilities
  • 62. MEXICO OPERATIONS • Centrally located in Queretaro, Mexico • Premier printer for Latin America & Mexico for 50 years • Centralized design, local manufacturing • Top quality manufacturing, equivalent to USA • Continuous improvement/lean environment • ISO/TS* 16949 certified • ISO 14001** certified *Additional standard for the German Automotive Manufacturers **Environmental certification
  • 66. OVERVIEW • Serigraph’s Continuous Improvement Journey • Management System – Tiered Dashboards – MDI – SQDC – Gemba – Coaching Kata – Leader Standard Work – Problem Solving • Next Steps
  • 67. LEAN CERTIFICATION 2005 CONTINUOUS IMPROVEMENT JOURNEY SIX SIGMA TRAINING 2011 HOSHIN KANRI 2012 2-SECOND LEAN 2014 4-STEP PROBLEM SOLVING 2014 SERIGRAPH MANAGEMENT SYSTEM 2016
  • 68. MANAGEMENT SYSTEM – Make gaps visible – Drive improvement through problem solving
  • 69. • TRUE NORTH – What do we want to be? • Tier 1 (monthly) – Translates True North goals into metrics – Balanced dashboard, offsetting metrics – Not directly actionable • Tier II (monthly, weekly, daily) – Balanced dashboard and MDI – KPIs to achieve Tier I targets – Directional, not directly actionable • Tier III (monthly, weekly, daily) – Balanced dashboard and MDI – KPIs to achieve Tier II targets – Actionable – where the A3s live • Tier IV (daily, hourly) – Simple metrics – Directly actionable – Alert to the current situation – Where ‘just do it’ problem solving happens DASHBOARD DEVELOPMENT
  • 70. DASHBOARD DEVELOPMENT Serigraph Inc. IG - North America Tier I Dashboard True North: Solve Problems We Will FY2016 Jul-16 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 FY2017 Gap Where Pareto Items (Row 1: Pareto Item Description; Row 2: Impact to Gap) Actual $ Target $ Actual Days Target Days Actual Incidents 4 1 1 0 0 2 S0272M S0220S Target (LY) Incidents 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Strain (occurred in May 2016) Slipped in lunch room (elbow) Actual # 326 39 33 16 13 101 Quality Color Lab Proj Mgmt Target # 328 42 33 16 13 0 0 0 0 0 0 0 0 104 1 1 1 Actual %of Cost 13.3% 17.3% 15.0% 14.1% 11.7% 14.6% Visteon (3 Accts) M1182 Marquardt S1403 Continental J1043M Jabil Luxembourg Target %of Cost 13.6% 12.0% 11.5% 11.0% 10.5% 10.0% 9.5% 9.0% 9.0% 9.0% 9.0% 9.0% 9.0% 11.3% 1.0% 0.5% 0.5% 0.2% Actual PPM 1,221 672 293 4,465 2,035 1,326 Target PPM 1,916 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 1,066 Actual % 93.0% 90.2% 89.5% 90.3% 88.9% 89.7% Conti Guad (85.4%; 158 late) Visteon (14.0%; 104 late) Calsonic (62.6%; 34 late) Delphi (63.2%; 28 late) Target % 96.5% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 96.0% 2.7% 2.3% 0.7% 0.6% Actual $,000 $54,741 $3,731 $4,572 $4,205 $3,823 $16,331 M1182 Marquardt R1178 RJR S1403 Continental G1044 GHSP Target $,000 $65,770 $4,910 $4,806 $4,653 $4,811 $4,685 $4,825 $4,560 $4,040 $4,493 $4,211 $4,324 $4,014 $19,180 ($1,188) ($960) ($547) ($401) Actual $ $33,798 $2,183 $2,864 $2,612 $2,406 $10,064 R1178 RJR S1403 Continental M1182 Marquardt H1016 Honda Target $ $39,289 $3,093 $2,964 $2,867 $2,963 $2,893 $2,977 $2,864 $2,535 $2,826 $2,632 $2,715 $2,529 $11,888 ($651) ($468) ($434) ($304) Actual % 61.7% 58.5% 62.6% 62.1% 62.9% 61.6% Target % 59.7% 63.0% 61.7% 61.6% 61.6% 61.7% 61.7% 62.8% 62.8% 62.9% 62.5% 62.8% 63.0% 62.0% Actual $,000 $31,446 $2,235 $2,576 $2,348 $2,467 $9,626 Target $,000 $32,959 $2,657 $2,733 $2,596 $2,655 $2,635 $2,865 $2,626 $2,348 $2,741 $2,397 $2,662 $2,538 $10,642 Actual $,000 $5,242 $125 $628 $1,068 $307 $2,128 Automotive Power Sports Appliance Consumer Products Target $,000 $13,793 $900 $1,000 $700 $900 $1,000 $1,200 $1,200 $1,200 $1,200 $1,200 $1,200 $1,200 $3,500 $3,799 $2,575 $2,360 $1,926 Actual $,000 $8,534 $169 $1,031 $1,867 $497 $3,563 Automotive Power Sports Appliance Consumer Products Target $,000 $22,934 $1,440 $1,600 $1,120 $1,440 $1,600 $1,920 $1,920 $1,920 $1,920 $1,920 $1,920 $1,920 $5,600 $5,892 $4,324 $4,069 $2,425 Actual % 61.4% 73.9% 60.9% 57.2% 61.8% 59.7% Target % 60.1% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% 62.5% Scrap (Internal Quality) On-Time Personnel Evaluations People Fixed Cost $'s Sales (Excluding Tooling) (3) -3.3% Cost Scrap (External Quality) TrueNorth Days Sales Outstanding + Days In Inventory (3 Month Rolling) New Business Awarded (FY2017 CM $) P.O. Line Items Shipped per Customer Request Date Safety (Lost Time + Recordables) Operating Profit Delivery Contribution Margin $ (Excluding Tooling) Contribution Margin % (Excluding Tooling) GrowthQuality New Business Awarded (FY2017 CM %) New Business Awarded (FY2017 Annual Sales $) (2) Operations ($1,372) Top 3 customers make up 60% of our miss to YTD target Full Year CM$ Gap ($2,037) Full Year Sales$ Gap Accounts driving Oct-16 late deliveries ($2,849) $3.096 of variance with these 4 customers ($1,824) $1.858 of variance with these 4 customers -6.3%
  • 72. DASHBOARD DEVELOPMENT • Suppliers, Inputs, Process, Outputs, Customers • Worked with each functional area to determine their ‘output’ and the critical requirements of each – Launch & Engineering – Tooling and Routing – Human Resources – Employees – Sales – Statement of Work, Promise to Buy Parts – Operations – Customer Parts • Translate those critical requirements into metrics S I P O CR R
  • 73. DASHBOARD DEVELOPMENT Safety Zone: Metric: Target: 29 30 31 28 15 16 17 18 19 20 21 22 23 24 25 26 27 7 8 9 10 11 12 13 14 1 2 3 4 5 6 Safety Incidents IG Ops 0 Quality Zone: Metric: Target: IG Ops <9% 29 30 31 21 22 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 13 14 1 2 3 4 5 6 Scrap % of Cost Delivery Zone: Metric: Target: IG Ops Ship Lines On Time >97% 29 30 31 21 22 23 24 25 26 27 28 15 16 17 18 19 20 7 8 9 10 11 12 13 14 1 2 3 4 5 6 Cost Zone: Metric: Target: Utilization IG Ops > 62% 7 8 9 10 11 12 13 14 1 2 3 4 5 6 21 22 23 24 25 26 27 28 15 16 17 18 19 20 29 30 31 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 July Aug Sep Oct Nov Dec Jan Feb Mar April May Jun Total 0Value Safety Incidents #ofIncidents History 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 July Aug Sep Oct Nov Dec Jan Feb Mar April May Jun Total 0Value Safety Incidents #ofIncidents History 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 July Aug Sep Oct Nov Dec Jan Feb Mar April May Jun Total 0Value Safety Incidents #ofIncidents History 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 July Aug Sep Oct Nov Dec Jan Feb Mar April May Jun Total 0Value Safety Incidents #ofIncidents History 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 Issue#LineItemsLatebyCustomer Miss Pareto 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 Issue#LineItemsLatebyCustomer Miss Pareto 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 Issue#LineItemsLatebyCustomer Miss Pareto 105 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 0 Issue#LineItemsLatebyCustomer Miss Pareto Status Problem-Solving Location A3 Yes or No Identified By Date Identifie d Shift Quantified Impact on Gap Due Date Assigned To Date Closed 1 2 3 4 5 6 7 8 9 10 11 12 13 Continuous Improvement Countermeasure Status Issue Countermeasure Status Problem-Solving Location A3 Yes or No Identified By Date Identifie d Shift Quantified Impact on Gap Due Date Assigned To Date Closed 1 2 3 4 5 6 7 8 9 10 11 12 13 Continuous Improvement Countermeasure Status Issue Countermeasure Status Problem-Solving Location A3 Yes or No Identified By Date Identifie d Shift Quantified Impact on Gap Due Date Assigned To Date Closed 1 2 3 4 5 6 7 8 9 10 11 12 13 Continuous Improvement Countermeasure Status Issue Countermeasure Status Problem-Solving Location A3 Yes or No Identified By Date Identifie d Shift Quantified Impact on Gap Due Date Assigned To Date Closed 1 2 3 4 5 6 7 8 9 10 11 12 13 Continuous Improvement Countermeasure Status Issue Countermeasure Are we winning or losing? By how much? What are the top causes? Are there people on it?
  • 75. GEMBA - PPO • Purpose – Take responsibility – Drive Performance – understand how and when gaps will be closed – Develop the problem solving capabilities of our people – Reinforce our values and celebrate our wins • Process – Verify completion of previous commitments from last Gemba – Review current red conditions and trends – Review pareto data for direct causes – Confirm issue is on countermeasure sheet – Review/coach problem solving • Outcome – Plan for improvement (who and when)
  • 76. GEMBA • Coaching Kata – What is the Target Condition? – What is the Actual Condition now? • Reflection on last step taken – What Obstacles are preventing you from reaching your Target Condition? • Which ONE are you addressing now? – What is your Next Step? • What do you expect? – How quickly can we go and see what we Have Learned from taking that step?
  • 78. GEMBA - LEADER STANDARD WORK Goals of Standard Work: 1. Seek Understanding 2. Set Expectations 1-Nov 2-Nov 3-Nov 4-Nov 7-Nov 8-Nov 9-Nov 10-Nov 11-Nov 14-Nov 15-Nov 16-Nov 17-Nov 18-Nov 21-Nov 22-Nov 23-Nov 24-Nov 25-Nov 28-Nov 29-Nov 30-Nov Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F 1:00 2:00 3:30 1:00 8:00 9:30 3:30 Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F 9:30 all day Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F 1day Time M T W Th F M T W Th F M T W Th F M T W Th F M T W Th F August Tier II Launch Hoshin PDCA Bi-Weekly A3 Inventory Tier I Tier II Operations - M X Populate SQDC Annual Review Scrap from Yesterday's Closed WOs Open A3 Tier II Operations - WB Tier I Dashboard Review STANDARD WORK Standard Work = What I do to obtain a desired outcome Weekly NovemberSelect Month & Year: Tier II Sales - CP/M D 2016 Gembas Daily Tier II Sales - Auto Quarterly Personal Goal Setting EA M eeting Monthly Populate Tier II CI SQDC Black Belt Project Tier II Sales - Appl/PS Pla n Do C heck Act Go & See Pla n Do C heck Act Go & See Pla n Do C heck Act Go & See Pla n Do C heck Act Go & See Pla n Do C heck Act Go & See Pla n Do C heck Act Go & See
  • 79. PROBLEM SOLVING • To prevent recurrence of a problem by eliminating its cause • You can give a person fish or…
  • 80. 4 STEP PROBLEM SOLVING Problem Solving A3 Title Step 1: DO I HAVE A PROBLEM? Step 3: DID I TEST FOR CAUSE & EFFECT? a) What Should be Happening? a) Hypothesis: If _______________________________________________ b) What is Actually Happening? (How many? How often?) Then ___________________________________________ c) What is the Gap? b) Conduct Experiment(s) c) Test Results: d) What is the Impact? What Happens? ____________________________________ e.) Problem Statement: Why? ____________________________________________ Step 2: DO I KNOW THE CAUSE? d) Select Countermeasures: a) What is the Point of Cause? b) What is the Direct Cause(s)? (Show your work - Results of 5why, pareto, fishbone, etc) Step 4: DID I CONFIRM COUNTERMEASURES? a) What standards / work instructions need to be updated? b) How Will I Confirm a Good Condition? C) Who Will Check? c) What is the Root Cause(s)? d) How Frequent? e) How Long Will I Check? Plan Do Check Adjust Team : Start Date Last Activity Control Define Improve Analyze
  • 81. NEXT STEPS • Maintain consistency of kata during gembas • Improve our bench strength in coaching problem solving • Celebrate the wins
  • 85. Materion Milwaukee Inorganic Chemical Manufacturer Offer 2,000+ Chemicals We handle 70% of the periodic table every day!
  • 86. Why Kata? ■ Stumbled Upon Kata ■ Struggled with Common CI Issues: ▪Limited Engagement ▪Long, Drawn-Out Projects ▪Chasing Savings ▪Slow/Declining Growth
  • 87. How We Started ■ Operations Management Group ▪Toyota Kata book club ▪Just try Kata & learn as we go
  • 88. How We Started ■ Picked Urgent Business Need ■ Established Process Level Target Conditions ■ Added to MDI agenda (Managing for Daily Improvement) ■ Began PDCA & Coaching …then broadened to other Value Streams
  • 89. Gains Cultural Results ▪Floor level engagement ▪Trying, failing, and learning ▪Daily improvement discussion
  • 90. Gains Business Results ▪Widespread Improvements ▪Captured New Business ▪Also Improved Several Legacy Value Streams
  • 91. What We Learned ■ No roll-out plan is good ■ No roll-out plan is bad ■ Practice vs. training/explaining ■ Using a “challenge” is helpful ■ Process Analysis is important for shifting mindsets
  • 92. Next Steps ■ Get Current Ops Management Team Educated ■ Coaching, Coaching, Coaching ■ Process Analysis Continue to… KATA our KATA
  • 94. Lunch – Networking ▪ Lunch is outside the room in the hallway – Please help yourself ▪ Please return back to the room at 1:00pm to being Kata in the Classroom
  • 95. Kata in the Classroom Exercise
  • 96. KATA IN THE CLASSROOM EXERCISE v5.5 www.katatogrow.com
  • 97. Kata in the Classroom - Introduction • Student teams follow the Improvement Kata pattern to establish a goal and then experiment toward it from round to round. • Helps teach universal STEM skills for achieving challenging goals along uncharted paths: – Scientific & Creative Thinking – Collaboration – Communication www.katatogrow.com • 50-minute exercise to introduce a practical pattern of scientific thinking in an engaging way in schools • Combines practical scientific pattern with techniques of deliberate practice, to help make scientific thinking a teachable skill anyone can learn.
  • 98. Kata in the Classroom - Objectives 1. Teacher has a positive experience with the simple, clear four-step Improvement Kata pattern and uses same pattern for other activities and projects during the school year. – This is where student practice and repetition of scientific thinking comes from. – Consider where else you might apply the scientific four-step pattern of the Improvement Kata with your students! 2. Students experience initial practicing of a scientific, cross-curricular, "life skill" routine that can be used to achieve challenging goals in a variety of situations. www.katatogrow.com Main objective is to teach awareness that ideas need to be tested.
  • 100. A is a routine you practice, so it's pattern becomes an automatic habit that gives you some new skills! www.katatogrow.com
  • 101. Today we'll practice the pattern of the It's a scientific routine for achieving tough goals www.katatogrow.com
  • 102. Conduct Experiments to get there Grasp the Current Condition Establish your Next Target Condition Get the Direction or Challenge 1 2 3 4 THE FOUR STEPS OF THE IMPROVEMENT KATA APPROACH Poster www.katatogrow.com
  • 103. Conduct Experiments to get there Grasp the Current Condition Establish your Next Target Condition Get the Direction or Challenge 1 2 3 4 A FEW KEY POINTS • You don't have to reach the overall challenge right away. • The path is not predictable or straight. • You experiment to get to the next target condition, which makes it scientific. www.katatogrow.com
  • 104. For this exercise we'll build this 15-piece puzzle several times, and experiment with ways to do it faster www.katatogrow.com
  • 105. Do the entire exercise without the puzzle frame Go ahead and build the puzzle one time! Put the Frame Aside • Take the puzzle out of the bag and study the picture. • Remove the puzzle pieces from the frame. • Put the frame back in the bag. • Build the puzzle once, without timing it. www.katatogrow.com
  • 106. Choose a Team Name Select a Data Recorder  Write your team name on the forms in the kit Select a Timekeeper  Use the stop watch on your smartphone THREE THINGS TO DO NEXT: www.katatogrow.com
  • 107. TODAY'S GROUND RULES (1) "START Position" = - Puzzle pieces shuffled in random order - Pieces face down in one stack - Hands flat on the table - No talking, you're ready to go (2) All Teams Start Together a. Instructor calls "START" b. Build the puzzle (talking allowed) c. Note the elapsed time on your form (3) Don't Write on the Puzzle www.katatogrow.com
  • 108. LET'S ESTABLISH A BASELINE TIME FOR YOUR TEAM Record your times here Use this form www.katatogrow.com
  • 109. Now let's do the four steps of the Improvement Kata www.katatogrow.com
  • 110. Conduct Experiments to get there Grasp the Current Condition Establish your Next Target Condition Get the Direction or Challenge 1 Step 1: UNDERSTAND THE CHALLENGE 15 SECONDS www.katatogrow.com
  • 111. Key Points About: UNDERSTANDING THE CHALLENGE • We often face challenges in life. No need to worry, because you don't need to get all the way there right away! • A challenge often even gives us a useful sense of direction. www.katatogrow.com
  • 112. Conduct Experiments to get there Grasp the Current Condition Establish your Next Target Condition Get the Direction or Challenge Step 2: GRASP THE CURRENT CONDITION 2 What was your team's last baseline time? www.katatogrow.com 15 SECONDS
  • 113. • It's important to understand where you currently are, before you set your next goal (target condition). • Don't pull goals randomly out of the air. A team should feel like its goals are meaningful. Key Points About: GRASPING THE CURRENT CONDITION www.katatogrow.com
  • 114. Conduct Experiments to get there Grasp the Current Condition Establish your Next Target Condition Get the Direction or Challenge Step 3: ESTABLISH YOUR NEXT TARGET CONDITION 3 www.katatogrow.com 15 SECONDS
  • 115. • Break a big challenge down into smaller goals. • Set an easier and closer goal that's on the way to your challenge. When you get there you can set the next goal. Key Points About: ESTABLISHING YOUR NEXT TARGET CONDITION www.katatogrow.com
  • 116. What puzzle build time does your team want to reach by the end of today's class? Conduct Experiments to get there Grasp the Current Condition Establish your Next Target Condition Get the Direction or Challenge LET'S DEFINE YOUR TEAM'S NEXT TARGET CONDITION www.katatogrow.com We can do five (5) rounds of experimenting today 15 SECONDS
  • 118. LET'S ASK EACH TEAM www.katatogrow.com
  • 119. DRAW YOUR TARGET CONDITION LINE ON THE 'EXPERIMENTING' FORM TC www.katatogrow.com
  • 120. Conduct Experiments to get there Grasp the Current Condition Establish your Next Target Condition Get the Direction or Challenge Step 4: CONDUCT EXPERIMENTS TO GET THERE 4 www.katatogrow.com 15 SECONDS
  • 121. • You never know in advance exactly how you will achieve a goal or target condition. • We need to test the ideas we have. A good way to reach a goal is to experiment rapidly. Try something, see what happens, and then adjust based on what you learn. • To learn from an experiment you should write down what you expect and what actually happens, so you can compare those two things. Key Points About: EXPERIMENTING TO GET THERE www.katatogrow.com
  • 122. HOW WE'LL EXPERIMENT 3 Minutes per Round Instructor calls "START" Build the puzzle Note the elapsed time on your form Based on what happened, discuss what you plan to do next Write ideas you want to test onto the form www.katatogrow.com
  • 123. (Before) Write down the next ideas you want to test (After) Write in how much the time changed compared to the last round (After) Mark the elapsed time THE EXPERIMENTING FORM What to record in each round www.katatogrow.com
  • 124. PLEASE PLAN YOUR FIRST EXPERIMENT Write the ideas you want to test next on your 'Experimenting' form Write down the ideas you want to test www.katatogrow.com
  • 126. AFTER EACH EXPERIMENT WE'LL REFLECT After each round we'll ask one team this set of Reflection Questions www.katatogrow.com
  • 127. GET READY FOR ROUND 1 3 Minutes per Round Instructor calls "START" Build the puzzle Note the elapsed time on your form Discuss what you plan to do next Write ideas you want to test onto the form ---------- Time's up... Ask the Reflection Questions Get into START Position (timekeeper raise hand) www.katatogrow.com
  • 129. GET READY FOR ROUND 2 3 Minutes per Round Instructor calls "START" Build the puzzle Note the elapsed time on your form Discuss what you plan to do next Write ideas you want to test onto the form ---------- Time's up... Ask the Reflection Questions Get into START Position (timekeeper raise hand) www.katatogrow.com
  • 131. GET READY FOR ROUND 3 3 Minutes per Round Instructor calls "START" Build the puzzle Note the elapsed time on your form Discuss what you plan to do next Write ideas you want to test onto the form ---------- Time's up... Ask the Reflection Questions Get into START Position (timekeeper raise hand) www.katatogrow.com
  • 133. GET READY FOR ROUND 4 3 Minutes per Round Instructor calls "START" Build the puzzle Note the elapsed time on your form Discuss what you plan to do next Write ideas you want to test onto the form ---------- Time's up... Ask the Reflection Questions Get into START Position (timekeeper raise hand) www.katatogrow.com
  • 135. GET READY FOR ROUND 5 3 Minutes per Round Instructor calls "START" Build the puzzle Note the elapsed time on your form Discuss what you plan to do next Write ideas you want to test onto the form ---------- Time's up... Ask the Reflection Questions Get into START Position (timekeeper raise hand) www.katatogrow.com
  • 137. What are the four steps of the Improvement Kata approach? Where else can we use the four-step pattern of the Improvement Kata? www.katatogrow.com
  • 138. What’s Next? • Run Kata in the Classroom on an In-service day for teachers • Think how you might deploy within a school system as part of STEM – Think of KiC deployment as a kata itself – Rapid low cost trials – Share learning and develop teacher / student capacity www.katatogrow.com For others • This is a quick way to introduce kata into a company setting • There are other simulations that also can be used (both with or without the puzzle) For School Systems:
  • 139. Run a Kata in the Classroom Exercise • Instructions are a “starter kata” • Steps and underlying principles of the Improvement Kata are broadly applicable. • First run the exercise as designed (to get the thinking pattern behind it) then adapt and use to suit your situation and purpose. www.katatogrow.com KiC Community • Share your experiences with other teachers; send email to kata.classroom@gmail.com with: • Photographs of your running of the KiC exercise. • What you learn from conducting the KiC exercise, including suggestions for improving it. • In what ways you adjust the exercise to meet your needs. • Examples of how you apply the 4-step pattern of the Improvement Kata to other student assignments, projects, etc. Creative Commons Copyright The Kata in the Classroom (KiC) materials are licensed under a Creative Commons Attribution- NonCommercial-ShareAlike license. You are free to copy, use, remix, transform, build upon and redistribute them as long as you note the source as katatogrow.com. However, these materials may not be used for sale in any form. Use them, adapt them, share them. KiC materials are free to download at www.katatogrow.com
  • 140. A REFERENCE CARD on the back of your Reflection Card www.katatogrow.com
  • 142. KATA – Learning at All Levels Mark Niemi Sr. Director of Operations TIDI Products, LLC
  • 147. ▪ Non-Acute Care Market leader in infection prevention products ▪ #1 market share in core “paper” offering for both physician and dental offices ▪ Growth Focus on acute care consumable and durables products ▪ Large, established customer base ▪ 3,000+ customers with 22-year tenure for top 10 customers ▪ Lean Manufacturing ▪ Continuous Improvement culture “Supporting Caregivers and Preventing Infections”
  • 148. Facility Overview Facility Year Established Employees Capabilities Neenah, WI 1985 260 Non Acute Care Consumables TIDI Paper and Tissue based products, Clean Room, Eyewear, Custom Barriers and Securement Fenton, MI 2001 122 Acute Care Durables Patient Positioning and Zero-Gravity Flint, MI 2013 17 Clean Room and Distribution Center Changshu, China 2006 215 Acute Care Consumables C-Armor and Large Equipment Barriers
  • 149. Non-Acute Care Consumables ▪ Grip-Lok® Securement ▪ Suite of patented catheter and line securement adhesive products ▪ Technology is used for holding tubes and catheters in place to prevent infections and needle stick for practitioners ▪ End markets include Alternate Site and dialysis
  • 150. Acute Care Durables ▪ Zero GravityTM System ▪ Suspended radiation protection system ▪ Replaces traditional heavy lead apparel, eliminating body strain inherent to traditional methods
  • 151. Acute Care Consumables ▪ C-Armor® Drape ▪ Expandable and collapsible sterile draping pouch. ▪ Reduces infection risk and complies with strict AORN standards ▪ Focused on OR end market
  • 153. Lean Management System Easy to say, hard to do ▪ Long term goals ▪ Create a plan ▪ Measure the plan ▪ Review the plan ▪ Use the scientific method ▪ So… just get started! ▪ Learn and improve as you go
  • 154. TIDI Management System Model What problem are we trying to solve? Achieve our long-term goals: Grow EBITDA to $XXM (non-acquisition) Grow Sales $XXXM (non-acquisition) Grow Gross Margin X% annually Grow EBITDA $XXM thru Acquisition Commitment to Continuous Improvement Values & Principles Create Alignment & Constancy of Purpose Process Improvement What are we trying to improve? Strategy Deployment 2017 Plans Master A3’s Focus A3’s Supporting A3’s Capability Development How are we building leadership capability & capacity? Leadership assessment & plan A3 Thinking & Coaching Problem Solving (PDCA) Daily Improvement (Kata) Project Management Rapid Improvement Events Value Stream Mapping Lean Management System • Leaders Standard Work • Visual Management • Regular Accountability & Support Meetings • Leadership Discipline
  • 156. Lean Management System Definition The leadership behavior that provides the glue to ensure strategy deployment & capability development are operating as intended (meeting the long term goals) and is continually improving Principles of a good Lean Management System ▪ Focused and connected to long term goals ▪ Drives continuous improvement ▪ A learning by doing process ▪ Utilizes the scientific method
  • 157. Lean Management System Components 1. Leader Standard Work 2. Visual Controls 3. Regular Accountability & Support Meetings 4. Leadership Discipline
  • 158. Leader Standard Work Definition Provides a structure and routine that shifts leaders from a sole focus on results to a dual focus on process plus results ▪ The “paper” (documented Leader Standard Work) describes the routine ▪ A list of normal actions that must be done to sustain the TIDI Management System ▪ Typically includes regular meetings, audits, and reviews ▪ Focused on the process ▪ Connects the leader to visual controls & A3 plans
  • 159. Leader Standard Work Example ▪ Bold items are the Lean Management System elements that support your A3 actions and goals ▪ Non-bolded items are flexible and available for each individual to help them manage their day/week/month Author Mark Niemi Last Revised 10/17/2016 What Responsibility When Frequency Details Cross-functional Huddle Own, Delegate 8:30 AM Daily Use agenda posted at visual control board Weekly Operations Meeting Participate Scheduled Weekly Enter update into OneNote before meeting Operations Leadership Meeting Own, Lead Scheduled Weekly 3 weeks per month, review scorecard & actions + team development. 1 week per month, review financials Strategy Deployment Review Participate Scheduled Monthly Update bowling chart before the meeting 1 on 1 meetings with each member of leadership team Own, Lead Scheduled Monthly Review top 3 things, lessons learned, next steps, personal development plan, & how can I help? Strategic Planning Event Participate October Annually As part of COO / VP team Strategic Planning Event Own, Lead November Annually Create plan for Neenah using startegy A3 process Value Stream Mapping Event Own, Delegate, Participate November Annually Create RCI plan for Neenah using value stream mapping process Kaizen Report Out Meetings Participate Scheduled On demand Review email for urgent & important issues Own Morning Daily Follow-up with appropriate leaders Review Neenah scorecard Own Before huddle Daily Look for key gaps to be disussed before Cross-functional Huddle meeing End of first shift hand-off meeting Own, Delegate, Participate 1:45 PM Daily Attend occasionally to ensure discipline to the process Update Neenah scorecard Own 1st TIDI day Monthly Create scorecard for new month. Delegate after established - January 2017? Safety meetings Own, Delegate, Participate Scheduled Monthly Attend as team member. Ensure discipline to the process and tangible results. Continuous Improvement Steering Committee Participate Scheduled Monthly Create budget Participate September Annually Neenah Director of Operations Standard Work Blue background with BOLD FONT indicates action critical to achieving Strategy Deployment goals
  • 160. Lean Management System Components ▪ Leader Standard Work ▪ Visual Management ▪ Regular Accountability & Support Meetings ▪ Leadership Discipline
  • 161. Visual Management Definition Something anyone can go to and clearly learn the status of the process they are reviewing. Allows you to see normal from abnormal and trends. Must be connected to the goals on your A3. ▪ This can be a bowling chart, graphs, dashboard, or management visual boards ▪ Can include problem solving tracking, lessons learned, obstacles, follow up, etc. ▪ Leader standard work should direct you to the visual controls
  • 162. Examples Metric Owner Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Plan(Mo.) $17,654,760 $14,798,504 $14,464,257 $17,853,193 $13,961,185 $14,152,891 $17,518,746 $15,059,050 $15,195,122 $17,544,327 $14,384,998 $14,733,372 Actual(Mo.) $16,643,910 $13,106,354 $13,680,407 $18,569,270 $14,133,515 $14,590,516 $16,622,101 $14,414,973 $14,122,572 $18,334,559 Plan(YTD) $17,654,760 $32,453,264 $46,917,521 $64,770,714 $78,731,899 $92,884,789 $110,403,536 $125,462,586 $140,657,707 $158,202,034 $172,587,032 $187,320,403 Actual(YTD) $16,643,910 $29,750,264 $43,430,671 $61,999,941 $76,133,456 $90,723,972 $107,346,073 $121,761,046 $135,883,618 $154,218,177 Plan(Mo.) $3,325,443 $2,980,946 $2,923,229 $3,591,691 $3,135,207 $3,062,321 $3,507,319 $3,303,069 $3,271,561 $3,607,855 $3,427,828 $3,461,319 Actual(Mo.) $3,478,885 $2,689,168 $2,768,840 $3,683,290 $3,081,465 $3,314,273 $3,714,276 $2,996,741 $3,107,359 $4,128,306 Plan(YTD) $3,325,443 $6,306,388 $9,229,617 $12,821,308 $15,956,516 $19,018,836 $22,526,156 $25,829,225 $29,100,786 $32,708,641 $36,136,470 $39,597,788 Actual(YTD) $3,478,885 $6,168,053 $8,936,894 $12,620,183 $15,701,649 $19,015,921 $22,730,198 $25,726,939 $28,834,298 $32,962,605 Plan(Mo.) $3,445,111 $2,746,803 $2,923,937 $3,424,362 $2,589,752 $2,719,858 $3,266,582 $2,656,317 $2,846,420 $3,022,957 $2,746,777 $3,061,919 Actual(Mo.) $2,833,959 $2,588,090 $2,338,172 $3,307,198 $2,522,085 $2,748,578 $3,049,141 $2,764,095 $2,639,076 $3,740,212 Plan(YTD) $3,445,111 $6,191,914 $9,115,851 $12,540,212 $15,129,964 $17,849,822 $21,116,404 $23,772,721 $26,619,141 $29,642,098 $32,388,875 $35,450,793 Actual(YTD) $2,833,959 $5,422,049 $7,760,221 $11,067,419 $13,589,504 $16,338,082 $19,387,223 $22,151,318 $24,790,394 $28,530,605 Plan(Mo.) $10,980,219 $9,150,182 $8,692,673 $10,932,781 $8,308,913 $8,444,458 $10,839,465 $9,156,966 $9,156,966 $11,008,896 $8,282,343 $8,282,343 Actual(Mo.) $10,324,179 $7,803,333 $8,486,026 $11,639,305 $8,532,937 $8,519,807 $9,857,654 $8,634,732 $8,366,207 $10,351,172 Plan(YTD) $10,980,219 $20,130,401 $28,823,074 $39,755,854 $48,064,768 $56,509,226 $67,348,691 $76,505,657 $85,662,623 $96,671,519 $104,953,863 $113,236,206 Actual(YTD) $10,324,179 $18,127,512 $26,613,537 $38,252,842 $46,785,780 $55,305,586 $65,163,240 $73,797,972 $82,164,179 $92,515,351 Plan(Mo.) $3,573,368 $3,013,573 $2,779,858 $3,610,953 $2,607,009 $2,710,789 $3,224,443 $2,952,354 $2,963,442 $3,230,211 $2,761,133 $2,963,881 Actual(Mo.) $3,619,654 $2,886,625 $2,452,094 $4,157,935 $2,836,655 $3,363,658 $3,948,887 $3,433,387 $3,328,454 $4,568,095 Plan(YTD) $3,573,368 $6,586,941 $9,366,799 $12,977,753 $15,584,762 $18,295,551 $21,519,994 $24,472,348 $27,435,790 $30,666,001 $33,427,135 $36,391,015 Actual(YTD) $3,619,654 $6,506,279 $8,958,373 $13,116,308 $15,952,963 $19,316,621 $23,265,508 $26,698,895 $30,027,349 $34,595,444 Plan(Mo.) 43.3% 43.4% 43.8% 43.6% 43.4% 43.6% 42.4% 43.1% 43.0% 42.6% 43.4% 44.0% Actual(Mo.) 42.8% 46.0% 42.0% 43.6% 43.1% 45.7% 45.7% 46.9% 46.3% 47.9% Month+/- -0.5% 2.6% -1.8% 0.0% -0.3% 2.0% 3.3% 3.7% 3.3% 5.3% Plan(YTD) 43.3% 43.3% 43.5% 43.5% 43.5% 43.5% 43.3% 43.3% 43.3% 43.2% 43.2% 43.3% Actual(YTD) 42.8% 44.3% 43.6% 43.6% 43.5% 44.8% 44.1% 44.4% 44.6% 45.0% Gross Sales Commercial Gross Sales - Acute Care Consumables Gross Margin % Gross Sales - Acute Care Durables Management EBITDA Mike Duski Mike Czop Jim Rubright Jeff Hebbard Gross Sales - Non- Acute Care Consumables Mike Duski
  • 163. Lean Management System Components ▪ Leader Standard Work ▪ Visual Controls ▪ Regular Accountability & Support Meetings ▪ Leadership Discipline
  • 164. Regular Accountability & Support Meeting Definition Regularly scheduled meetings with your team to review the process and results ▪ Meeting have standard agenda & questions ▪ Holds leader and team accountable to the process ▪ Discuss current condition, target condition and gaps ▪ Coach & support the owner
  • 166. Accountability & Support Meetings (back of leader standard work form) Author Mark Niemi Last Revised 10/17/2016 What Responsibility When Frequency Details Cross-functional Huddle Own, Delegate 8:30 AM Daily Use agenda posted at visual control board Weekly Operations Meeting Participate Scheduled Weekly Enter update into OneNote before meeting Operations Leadership Meeting Own, Lead Scheduled Weekly 3 weeks per month, review scorecard & actions + team development. 1 week per month, review financials Strategy Deployment Review Participate Scheduled Monthly Update bowling chart before the meeting 1 on 1 meetings with each member of leadership team Own, Lead Scheduled Monthly Review top 3 things, lessons learned, next steps, personal development plan, & how can I help? Strategic Planning Event Participate October Annually As part of COO / VP team Strategic Planning Event Own, Lead November Annually Create plan for Neenah using startegy A3 process Value Stream Mapping Event Own, Delegate, Participate November Annually Create RCI plan for Neenah using value stream mapping process Kaizen Report Out Meetings Participate Scheduled On demand Review email for urgent & important issues Own Morning Daily Follow-up with appropriate leaders Review Neenah scorecard Own Before huddle Daily Look for key gaps to be disussed before Cross-functional Huddle meeing End of first shift hand-off meeting Own, Delegate, Participate 1:45 PM Daily Attend occasionally to ensure discipline to the process Update Neenah scorecard Own 1st TIDI day Monthly Create scorecard for new month. Delegate after established - January 2017? Safety meetings Own, Delegate, Participate Scheduled Monthly Attend as team member. Ensure discipline to the process and tangible results. Continuous Improvement Steering Committee Participate Scheduled Monthly Create budget Participate September Annually Neenah Director of Operations Standard Work Blue background with BOLD FONT indicates action critical to achieving Strategy Deployment goals Standard Questions Agenda for Weekly Operations Meeting What is your target condition? Have notes from rpevious meeting for reference to ensure continuity What is the actual condition now? Assign a note taker to record what, who, when, and how for each action discussed What did you do as your last step? Review time allocated for this meeting (finish on time!) What did you expect? Review Neenah Scorecard What actually happened? Safety - ask the standard questions and record learning and next steps What did you learn? Quality - ask the standard questions and record learning and next steps What obstacles are keeping you from reaching the target condition? Delivery / Plan attainment - ask the standard questions and record learning and next steps Which one are you addressing now? Productivity - ask the standard questions and record learning and next steps What is you next step? People / Turnover - ask the standard questions andrecord learning and next steps What do you expect to happen? Review top 3 things for each team member with progress update How soon can we see what we have learned by taking that next step? Review all action items for agreement that we are working on the most important Adjust if necessary to ensure maximum progress Ensure each action item has what, who, when, and how agreed upon and recorded for next meeting Agenda for Monthly One-on-One Meetings Focus – What are your Top 3 things? Describe in a single sentence the intended successful outcome, in other words what would need to happen to check this project off as done? Write down the very next physical action required to move the situation forward Review A3’s Review departmental expense Review scorecard(s) Discuss team development Discuss personal development – including 2 lean leader behaviors Open discussion Agenda for Cross-Functional Huddle Posted in Huddle Board area
  • 167. Lean Management System Components ▪ Leader Standard Work ▪ Visual Controls ▪ Regular Accountability & Support Meetings ▪ Leadership Discipline
  • 168. Leadership Discipline Definition Finding the courage and resolve to learn, understand, and hold yourself and your team accountable to the lean management system ▪ Live and Learn the Lean Leadership Fundamental Behaviors ▪ Willingness … Reflection ▪ Humility … Go See, Listen, & Learn ▪ Curiosity … Ask Questions, Effective Listening, A3 Thinking ▪ Perseverance … Partner, Buddy System, Coach ▪ Self-Discipline … Leader Standard work ▪ Backsliding starts when something else becomes more important or we don’t have the discipline to adhere to the system
  • 169. How does this all fit? ▪ The key focus is strategy deployment ▪ Recognize there is other work that must be done ▪ Suggest only one leader standard work document ▪ Use bold for Strategy Deployment actions and non-bold for others ▪ Limit accountability & support meetings to what is absolutely necessary ▪ For example – direct report one on ones can cover both strategy deployment, daily continuous improvement and big rocks (top three priorities) Strategy Deployment LMS Daily Continuous Improvement Big Rocks True North
  • 170. Title: What change or improvement are you talking about? Owner/Date 1.Background: what are you talking about and why? What is the purpose, business reason for choosing this issue? What specific performance measure needs to be improved? What is the strategic, operational, historical, or organizational context of the situation? 2. Current Conditions: Where do things stand now? What is the problem or need – the gap in performance? What is happening now versus what you want or needs to be happening? Have you been to the Gemba? What facts or data indicate there is a problem? What specific conditions indicate that you have a problem or need? Where and how much? Can you break the problem into smaller pieces? Show facts and processes visually using charts, graphs, maps, etc. 3. Goals: What specific outcome is required? 4. Analysis: Why does the problem or need exist? 5. Recommendations: What do you propose and why? 6. Plan: How will you implement? (4W’s, 1H) 7. Follow-up: How will you ensure ongoing PDCA? What specific improvement (S) in performance you need to achieve? Show visually how much, by when, and with what impact. Don't state a countermeasure as a goal! What do the specifics of the issues in work processes (location, patterns, trends, factors) indicate about why the performance gap or need exists? What conditions or occurrences are preventing you from achieving the goals? Why do they exist? What is (are) their cause (S)? Use the simplest problem analysis tool that will suffice to show cause and effect down to the root cause. From 5 wise to 7 Q C tools (fish bones, analysis trees, Pareto charts, to more sophisticated SPC, 6 Sigma, and other tools as needed. Test the cause-and-effect logic by asking "why?" Downward and starting "therefore" upward. What are the options for addressing the gaps in improving performance the current situation? Always start with two or three alternatives to evaluate. How do they compare in effectiveness, feasibility, and potential disruption? What are their relative costs and benefits? Which do you recommend and why? Show your proposed actions will address the specific causes of the gaps strangely identified in your analysis. The link should be clear and explicit! What will be the main actions and outcomes in the implementation process and in what sequence? What support and resources will be required? Who will be responsible for what, when, and how much? How will you measure effectiveness? When will progress be reviewed and by whom? Use a Gantt chart (or similar diagram) to display actions, steps, outcomes, timeliness, and roles. How and when will you know if plans have been followed and actions have had the impact planned and needed? How you know if you met your targets? How will you know if you reduced the gap in performance? What related issues or unintended consequences do you anticipate? What contingencies can you anticipate? What processes will you use to enable, sure, and sustained success? How will you share your learnings with other areas? Strategy A3(s) Created Annually Neenah Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec SAFETY 2015 Act 0 2 2 0 0 1 0 1 2 2 0 2 RECORDABLES 2016 Act 0 1 0 2 0 0 4 5 1 0 2016 Plan 0 0 0 0 0 0 0 0 0 0 0 0 Performance 0 1 0 2 0 0 4 5 1 0 Note: Ergonomicassessmentwas done in September, awaitingresults forfurtherplanning. QUALITY 2015Act 0.50% 0.55% 0.62% 0.61% 0.60% 0.57% 0.78% 0.78% 0.58% 0.73% 0.73% 0.62% COST OF QUALITY 2016Act 0.76% 0.52% 0.52% 0.50% 0.66% 0.51% 0.73% 0.61% 0.60% 2016Plan 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% 0.50% Performance 152.0% 104.0% 104.0% 100.0% 132.0% 102.0% 146.0% 122.0% 120.0% Note: Shortage on shipmentfor3500on nose clip, investigatingshortage. PRODUCTIVITY 2015Act NA NA NA NA NA NA NA NA NA NA NA NA STD / ACT LABOR 2016Act 92.0% 102.0% 98.8% 98.5% 104.0% 99.8% 93.0% 96.6% 99.9% 2016Plan 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% Performance 92.0% 102.0% 98.8% 98.5% 104.0% 99.8% 93.0% 96.6% 99.9% Note: DELIVERY 2015Act 79.8% 96.7% 90.6% 92.3% 94.0% 96.3% 94.1% 96.9% 86.9% 98.3% 97.1% 92.6% CUSTOMER LINE FILL 2016Act 98.9% 98.8% 93.9% 98.5% 99.4% 99.3% 94.9% 93.8% 93% 2016Plan 97% 97% 97% 97% 97% 97% 97% 97% 97% 97% 97% 97% Performance 102.0% 101.9% 96.8% 101.5% 102.5% 102.4% 97.8% 96.7% 96.0% Note:Base stock items and large customers performance continues tobe atstandard. Continue tostruggle with staffingin shippingtocoverdaily spikes. INVENTORY 2015 Act 49 56 50 51 55 54 53 54 60 55 54 55 DIOH 2016 Act 64 66 63 57 58 60 68 69 70 2016 Plan 62 60 60 59 60 59 57 53 53 53 56 56 Performance 102.4% 110.0% 105.0% 96.6% 96.7% 101.7% 119.3% 130.2% 132.1% TIDI Monthly Operations KPI's by Facility Author Mark Niemi Last Revised 10/17/2016 What Responsibility When Frequency Details Cross-functional Huddle Own, Delegate 8:30 AM Daily Use agenda posted at visual control board Weekly Operations Meeting Participate Scheduled Weekly Enter update into OneNote before meeting Operations Leadership Meeting Own, Lead Scheduled Weekly 3 weeks per month, review scorecard & actions + team development. 1 week per month, review financials Strategy Deployment Review Participate Scheduled Monthly Update bowling chart before the meeting 1 on 1 meetings with each member of leadership team Own, Lead Scheduled Monthly Review top 3 things, lessons learned, next steps, personal development plan, & how can I help? Strategic Planning Event Participate October Annually As part of COO / VP team Strategic Planning Event Own, Lead November Annually Create plan for Neenah using startegy A3 process Value Stream Mapping Event Own, Delegate, Participate November Annually Create RCI plan for Neenah using value stream mapping process Kaizen Report Out Meetings Participate Scheduled On demand Review email for urgent & important issues Own Morning Daily Follow-up with appropriate leaders Review Neenah scorecard Own Before huddle Daily Look for key gaps to be disussed before Cross-functional Huddle meeing End of first shift hand-off meeting Own, Delegate, Participate 1:45 PM Daily Attend occasionally to ensure discipline to the process Update Neenah scorecard Own 1st TIDI day Monthly Create scorecard for new month. Delegate after established - January 2017? Safety meetings Own, Delegate, Participate Scheduled Monthly Attend as team member. Ensure discipline to the process and tangible results. Continuous Improvement Steering Committee Participate Scheduled Monthly Create budget Participate September Annually Neenah Director of Operations Standard Work Blue background with BOLD FONT indicates action critical to achieving Strategy Deployment goals Standard Questions Agenda for Weekly Operations Meeting What is your target condition? Have notes from rpevious meeting for reference to ensure continuity What is the actual condition now? Assign a note taker to record what, who, when, and how for each action discussed What did you do as your last step? Review time allocated for this meeting (finish on time!) What did you expect? Review Neenah Scorecard What actually happened? Safety - ask the standard questions and record learning and next steps What did you learn? Quality - ask the standard questions and record learning and next steps What obstacles are keeping you from reaching the target condition? Delivery / Plan attainment - ask the standard questions and record learning and next steps Which one are you addressing now? Productivity - ask the standard questions and record learning and next steps What is you next step? People / Turnover - ask the standard questions andrecord learning and next steps What do you expect to happen? Review top 3 things for each team member with progress update How soon can we see what we have learned by taking that next step? Review all action items for agreement that we are working on the most important Adjust if necessary to ensure maximum progress Ensure each action item has what, who, when, and how agreed upon and recorded for next meeting Agenda for Monthly One-on-One Meetings Focus – What are your Top 3 things? Describe in a single sentence the intended successful outcome, in other words what would need to happen to check this project off as done? Write down the very next physical action required to move the situation forward Review A3’s Review departmental expense Review scorecard(s) Discuss team development Discuss personal development – including 2 lean leader behaviors Open discussion Agenda for Cross-Functional Huddle Posted in Huddle Board area Focus: TIDI Operations Task No. Task Owner Target Date J F M A M J J A S O N D Status Next Step 1 BUILD A GREAT TEAM 1.1 Assess team & structure - Neenah, Fenton, China Jeff H. 6/1/16 - - - - > X In proces - N solid, F needs work, C solid but thin On board EB, coach JZ, leverage Neenah 1.2 Hire Operations Leader for Fenton Jeff H. 6/1/16 - - - - > X Complete 1.3 Complete team structure for Fenton Jeff H. 12/1/16 - - - - > X After Dir of Ops in place Work with EB, she needs some time to assess 1.4 Team development plans Jeff H. On going X X X X X X X X X X Started 1:1's - not mission critical right now 2 TIDI STRATEGY DEPLOYMENT 2.1 Top level X-Matrix completion Jeff H. / ELT 3/30/16 X Complete 2.1.1 6 Month Strategy Deployment Review (Kevin called this - add to std work for 2017) KM/ELT 6/15/16 X Complete 2.2 Deployment to organization - assist other departments on their deployment Jeff H. 3/30/16 X Complete Complete but opportunity for improvement 2.3 Monthly Strategy Deployment meeting Jeff H. / Mgmt On Going X X X X X X X X X X X X Meeting held with fully updated x-matrix 2.4 Achieve enterprise results ELT On Going X X X X X X X X X X X X Sales off, EBITDA on target, Margin on target, some WI RED Countermeasures identified - need to track 2.5 Reflection on 2016 and create 2017 process Jeff H. / ELT 12/31/16 X JH needs to take more ownership, take more time, and show more discipline to process 3 BUILD A LEAN MANAGEMENT PROCESS FOR OPERATIONS 3.1 Create Operations 2016 Business Plan - A3 Jeff H. 3/30/16 X Complete Review in monthly 1:1's 3.2 Create Operations 2016 key metrics - Bowling Chart Jeff H. 3/30/16 X Complete Review in monthly 1:1's 3.3 Deploy operations A3 and create departmental business plans & metrics (visual controls) Jeff H. 3/30/16 X Discussions & drafts done Starting review in monthly 1:1's 3.4 Determine accountability meeting structure - team, huddles, 1:1's (PDCA) Jeff H. On going X X X X X X X X X 3.5 Create Leader Standard Work Jeff H. X 3.6 Discipline to the process Jeff H. On going X X X X X X X X X 4 FENTON OPERATIONS IMPROVEMENT 4.1 Pick core team - define the current state (brutal reality) Jeff H. 3/1/16 X Complete 4.2 Pick one to two measures Jeff H. 4/18/16 X Complete Needs follow up on status 4.3 P/Q analysis - pick areas to attack Jeff H. 3/30/16 X Complete 4.4 Value Stream Map Event Jeff H. 4/18/16 X Complete 4.5 Complete Value Stream Map Action Plan Jeff H. On going X X X X X X X X In process Matress cell behind, others on target 4.6 Implement Lean Management System in Fenton Jeff H. 4/30/16 X No progress - need leader in place first 5 TIDI CONTINUOUS IMPROVEMENT - BUSINESS SYSTEM 5.1 Reflection event Jeff H / LSC 4/1/16 X Complete 5.2 Create Continuous Improvement A3 Jeff H. 4/1/16 X Complete 5.3 Assess staffing and leadership needs and build the team Jeff H. 6/1/16 - > X Still examining opportunities and need 5.4 Lean leadership training program Jeff H 11/1/16 - - - - - > X 5.5 Kaizen event planning and approval - build more robust process connected to True North & results desired Jeff H 12/1/16 - - - - - - > X Some progress since reflection, still needs work 5.6 Enhance problems solving and usage Jeff H 12/1/16 - - - - - - > X 6 CHINA OPERATIONS IMPROVEMENT 6.1 Visit China facility - first assessment Jeff H 5/15/16 X Complete 6.2 Create 2016 action plan and metrics Jeff H 6/1/16 X KPI's in place and being reported 6.3 Implement Lean Management System Jeff H On going X X X X X X X 7 REDUCE COMPLEXITY - SIMPLIFY THE BUSINESS (Margin Master A3) 7.1 80/20 PLS event Neenah Jeff H. 4/1/16 X Started - gaining momentum Work the plan 7.2 80/20 PLS event Fenton Jeff H. 6/1/16 X Started Need to see and assess plan 7.3 80/20 PLS event China Jeff H. 11/1/16 X 7.4 Cost Reduction - Material, Labor, Expense, CI Jeff H. On going X X X X X X X X X X X 8 OTHER 8.1 Asiste in Create / Improve the Product Development process No current plan 8.2 My personal education in all business processes Jeff H. On-going X X X X X X X X X X X On-going, Gemba walks, 1:1's Tradeshow, customer visits 8.3 Assist / Co-Lead Margin A3 Jeff H. On-going X X X X X X X X X X Taken over full responsibility More time with leaders Author: Jeff Hebbard Revision #: 4 Date: 6/22/2016 FY2017 Action Plan On Target Behind Target Trouble Action Plan(s) – updated monthly SD + DCI + Big Rocks Visual Controls – updated monthly Leader Standard Work
  • 171. Q&A
  • 173. Kata at Bradley Specialties GroupA division of Bradley Corporation Nate Rife – BOS Manager Josh Rauen – Manufacturing Supervisor
  • 175. Previous Lean Deployment • Focus on tools • Kaizen “Events” using the tools (typically 5S or VSM) • Large action lists • Difficult to sustain improvements • Improvements not always tied to process (therefore limited impact on plant level results)
  • 176. Our Kata Approach: building on our experience • Tools are the same… 5S, line balancing, setup reduction, etc. • The difference is in the kata structure (IK and CK) • Tools are only used to eliminate obstacles preventing achievement of the next TPC. • Not a “Management Fad”
  • 177. Kata on the Mirror Line Pre-Kata Current Condition People: 4/5 2, 3, 4, or 5 Flow: 1x1 (60 boxes) 1x1 (5 boxes) Cadence: CT = 34s (4 EE’s) CT = 34s, 49s, 64s Variance: 10s to 138s +/- 21s
  • 178. Operator Engagement thru PDCA ▪ Operators recording their own data for PDCA loops. ▪ Examples of exit cycle times for playbook manning options and line balancing ▪ Single Piece Flow (Wendy’s story)
  • 179. PDCA loops: using the tools to eliminate obstacles Std Work and Playbook Component Kanban Setup Reduction Line Balance 5S
  • 180. Mirror Line Results • Output from approximately 300 mirrors/day to up to 450 mirrors/day • OPR: from 45% to up to 63% • Output scalable to meet customer demand (takt) • Biggest benefit: Newfound capability in operator, re- assigned to drive continuous improvement in other areas.
  • 181. Not just the production process • Inventory Accuracy and the put-away process • Grab Bar escutcheon quality issue • Ubar 3P activity Current Future People 4 2-4 (adjustable) Flow 1 x 1 1 x 1 Cadence CT = 20 Sec/pc with one shift (2016 demand of 1160 bars/day) CT = 25 to 34 sec/pc with two shifts. (2019 demand of 1543 bars/day) Variance OPR = 60-85% OPR = 70-85% Ubar Line 3P Grab Bar Escutcheon Quality Problem
  • 182. Key Learning's • Partnering with someone who knows the kata approach was a huge benefit! • Smaller is better… we tend to set big TPC’s • Smaller TPC’s promote quicker PDCA cycles and simple solutions. Beware of waiting for the big solution (label printer) • Team creativity is priceless • Plant-level challenge helps set good TPC’s • Coaching is harder than we thought… we need a good plan (kata the kata)
  • 183. Kata the Kata A3: Plant Challenge/Cascading Dept Challenges Map of Improvement (StoryBoards) People: Jeff H, Jeff B, Nate R, Josh R, Rick S, Greg S, Jeff J Flow: 2 Week TPC’s, On track to Quarterly Dept Challenge Cadence: Weekly Variance: 80% Attendance
  • 186. 1. Learn more about Toyota Kata 2. Try it! 3. Rinse and Repeat Next Steps
  • 187. Visit the Toyota Kata Website… www- personal.umich.edu/~mrother/W hat_is_a_Kata.html Learn more about Toyota Kata
  • 188. Learn more about Toyota Kata Read the book…
  • 189. Talk to the Speakers… Learn more about Toyota Kata
  • 190. Learn more about Toyota Kata Attend the Conference… katasummit.com
  • 191. All the materials are available at: www.katatogrow.com Run the Kata in the Classroom exercise… Learn more about Toyota Kata
  • 192. Try it!!! Start small…Don’t be afraid to struggle
  • 193. Rinse and Repeat • Learn what works and what doesn’t work • Adjust and keep going • Kata your Kata… Obstacles - ??? Army of problem solvers You are here…
  • 195. Look for a survey in your inbox soon…