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- 1. Lean Management Teachers Our Improvement Story BoardIdeas building on Mike Rothers work using recent experience with beginning practitioners. March 2012 Emiel van Est
- 2. Our Improvement Story We practice the Improvement Kata & Coaching Kata as outlined in Mike Rothers Book Toyota Kata and the companion Handbook © Lean Management Teachers 2
- 3. We used the Process Analysis Mini Kata to Understand our Current Condition. 2 4 3 1We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision -- Example 2 -- All-in-one summary for a manual lineCustomer Demand and Line Pace Customer Demand / Line Pace CURRENT CONDITION• Customer takt• Planned cycle time • Takt Time = 30 seconds Process• Number of shifts currently running • PC/T = 22 seconds • Gap = 27% DateOverview of the Process • Running 2 Shifts + overtime• Define the start & end points of the process • 10 changeovers per day• Get to know the process by sketching a block diagram of it 40 Range of observed cycle times - Where does WIP accumulate? Overview• How much does process output fluctuate? (Cycle-to-cycle and shift-to-shift)• Note other details about the current operating pattern • Output cycles vary +/- 109% 35 Lowest repeatable • Operator work steps vary observed cycle time • 4 operators TTMachine Capacity • WIP (as shown)• Can the automatic equipment support the planned cycle time?• How close are we to our current machine capacity limit? No Yes • Line does not meet Pc/t 25• What is the fastest Pc/t the equipment can currently support? and must run overtime Pc/t• Shift options? 20 Machine Capacity 90% of Pc/tProcess Fluctuation • Op 90 cannot meet Pc/t 15• Time 20-40 full cycles of each operatorʼs work No Yes (see chart)• Are each operatorʼs work steps the same from cycle to cycle? 10 Process StabilityNecessary Number of Operators (if process were stable) • Operator cycles fluctuate I I I I• Calculate number of operators up to -30% / + 90% (see chart) 5 5 2 12 22 • Operator 4 cannot consistently pcs pcs pcs pcs meet Pc/t 10 40 70 90 110 Necessary Number of Operators Machines Operators • 3.2 operators / 4 actual • Operators 1, 2 & 3 are underutilized (see chart) © Improvement Kata Handbook Current Condition 50 © Lean Management Teachers 3
- 4. We filled in our Target Condition Form 2 4 3 1 We were Now we are here, We want ChallengeWHAT INFORMATION IS IN APDCA to overcome obstacles here using TARGET CONDITION? to be here & Vision A target condition describes how you want a process to operate • A target condition for a manufacturing process should include the following four categories of information. • No verbs in a target condition. Thatʼs for how to get there. • You must include a target date for achieving the target condition. Process: Challenge: TC date: Achieve-By Date: (required) Theme of this TC: (1) DESCRIBE PROCESS STEPS, SEQUENCE & TIMES Step 1: Step 2: Fill in what you will keep Fill in current Current Target A pattern you can draw or chart (see example) condition data Condition Condition the same Step 3: Fill in what you want to change (2) OTHER PROCESS CHARACTERISTICS Examples: • Number of operators Takt time: Takt time:Used for • Number of shifts proving • Where 1x1 flow is planned, and where standard WIP Pc/t: Pc/t: (incl. quantity) is to be located # of Shifts: # of Shifts: • Leveling sequence Overtime (how much): Overtime: (3) PROCESS METRIC(S) (Measurement in the moment) Output / Shift (run chart): Output / Shift: For checking process condition in real time # of Operators: # of Operators: Examples: • Time for each step, piece, pitch, etc. Where 1x1, where WIP: Where 1x1, where WIP: • Degree of time fluctuation from cycle to cycle Describe the process Describe the process steps, sequence, times: steps, sequence, times: Exit cycle fluctuation %: Exit cycle fluctuation %: (4) OUTCOME METRIC(S) Other observations about the current pattern:Used to To check outcome of improvement efforts check Examples: • Number of pieces per hour or shift • Leveling sequence attainmenttcomes • Productivity Process Metric: Outcome Metric:Improvement Kata Handbook Target Condition Kata Handbook © Improvement 11 Target Condition 23 © Lean Management Teachers 4
- 5. Now we are here mixing things up during coaching sessions. 2 4 3 1We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision © Lean Management Teachers 5
- 6. Quite often, Q2 is answered by the Current Condition we came from,.. 2 4 3 1We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision Process: Challenge: TC date: Theme of this TC: Step 1: Step 2: Fill in what Fill in current you will keep Current Target the same condition data Condition Condition Step 3: Fill in what you want to change Takt time: Takt time: Pc/t: Pc/t: # of Shifts: # of Shifts: Overtime (how much): Overtime: Output / Shift (run chart): Output / Shift: # of Operators: # of Operators: Where 1x1, where WIP: Where 1x1, where WIP: Describe the process Describe the process steps, sequence, times: steps, sequence, times: Exit cycle fluctuation %: Exit cycle fluctuation %: Other observations about the current pattern: Process Metric: Outcome Metric: © Improvement Kata Handbook Target Condition 23 © Lean Management Teachers 6
- 7. ... instead of referring to Todays Current Condition … 2 4 3 1We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision Our Gemba Go & See © Lean Management Teachers 7
- 8. … or this section is updated every PDCA cycle 2 4 3 1We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision Process: Challenge: TC date: Theme of this TC: Step 1: Step 2: Fill in what Fill in current you will keep Current Target the same condition data Condition Condition Step 3: Fill in what you want to change Takt time: Takt time: Pc/t: Pc/t: # of Shifts: # of Shifts: Overtime (how much): Overtime: Output / Shift (run chart): Output / Shift: # of Operators: # of Operators: Where 1x1, where WIP: Where 1x1, where WIP: Describe the process Describe the process steps, sequence, times: steps, sequence, times: Exit cycle fluctuation %: Exit cycle fluctuation %: Other observations about the current pattern: Process Metric: Outcome Metric: © Improvement Kata Handbook Target Condition 23 © Lean Management Teachers 8
- 9. Lean Management TeachersMaybe we can make things easier to understand © Lean Management Teachers 9
- 10. Lets cut the Target Condition Form in two and add a date for the starting Current Condition to clearly distinct starting point and targeted point. 2 4 3 1 We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & VisionProcess: Challenge: TC date: Process: Challenge: TC date: Theme of this TC: Theme of this TC: Step 1: Step 2: Fill in what Step 1: Step 2: Fill in what Fill in current you will keep Fill in current you will keep Current Target the same Current Target the same condition data Condition condition data Condition Condition Condition Step 3: Fill in what Step 3: Fill in what you want to change you want to changeTakt time:Pc/t: Date Takt time: Pc/t: Takt time: Pc/t: Takt time: Pc/t:# of Shifts: # of Shifts: # of Shifts: # of Shifts:Overtime (how much): Overtime: Overtime (how much): Overtime:Output / Shift (run chart): Output / Shift: Output / Shift (run chart): Output / Shift:# of Operators: # of Operators: # of Operators: # of Operators:Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP:Describe the process Describe the process Describe the process Describe the processsteps, sequence, times: steps, sequence, times: steps, sequence, times: steps, sequence, times:Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %:Other observations about the current pattern: Other observations about the current pattern: Process Metric: Process Metric: Outcome Metric: Outcome Metric: © Improvement Kata Handbook Target Condition © Improvement Kata Handbook 23 Target Condition 23 © Lean Management Teachers 10
- 11. In between we can list all relevant information about our discovery process. 2 4 3 1 We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & VisionProcess: Challenge: TC date: Process: Challenge: TC date: Theme of this TC: Theme of this TC: Step 1: Step 2: Fill in what Step 1: Step 2: Fill in what Fill in current you will keep Fill in current you will keep Current Target the same Current Target the same condition data Condition condition data Condition Condition Condition Step 3: Fill in what Step 3: Fill in what Date you want to change you want to changeTakt time: Takt time: Takt time: Takt time:Pc/t: Pc/t: Pc/t: Pc/t:# of Shifts: # of Shifts: # of Shifts: # of Shifts:Overtime (how much): Overtime: Overtime (how much): Overtime:Output / Shift (run chart): Output / Shift: Output / Shift (run chart): Output / Shift:# of Operators: # of Operators: # of Operators: # of Operators:Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP:Describe the process Describe the process Describe the process Describe the processsteps, sequence, times: steps, sequence, times: steps, sequence, times: steps, sequence, times:Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %:Other observations about the current pattern: Our Gemba about the current pattern: Other observations Go & See Process Metric: Process Metric: Outcome Metric: Outcome Metric: © Improvement Kata Handbook Target Condition © Improvement Kata Handbook 23 Target Condition 23 © Lean Management Teachers 11
- 12. Lean Management Teachers Lets test our redesignedImprovement Story Board © Lean Management Teachers 12
- 13. Our Improvement Story Q1 Our Target Condition 2 4 3 1 We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision Process: Challenge: TC date: Process: Challenge: TC date: Theme of this TC: Theme of this TC: Step 1: Step 2: Fill in what Step 1: Step 2: Fill in what Fill in current you will keep Fill in current you will keep Current Target the same Current Target the same condition data Condition condition data Condition Condition Condition Step 3: Fill in what Step 3: Fill in what Date you want to change you want to change Takt time: Takt time: Takt time: Takt time: Pc/t: Pc/t: Pc/t: Pc/t: # of Shifts: # of Shifts: # of Shifts: # of Shifts: Overtime (how much): Overtime: Overtime (how much): Overtime: Output / Shift (run chart): Output / Shift: Output / Shift (run chart): Output / Shift: # of Operators: # of Operators: # of Operators: # of Operators: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Describe the process Describe the process Describe the process Describe the process steps, sequence, times: steps, sequence, times: steps, sequence, times: steps, sequence, times: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Other observations about the current pattern: Other observations about the current pattern: -- Example 2 -- All-in-one summary for a manual lineCustomer Demand / Line Pace CURRENT CONDITION Process Metric: Process Metric: • Takt Time = 30 seconds Process • PC/T = 22 seconds Outcome Metric: Outcome Metric: • Gap = 27% Date • Running 2 Shifts + overtime • 10 changeovers per day © Improvement Kata Handbook Target Condition 23 © Improvement Kata Handbook Target Condition 23 40 Range of observed cycle timesOverview • Output cycles vary +/- 109% 35 Lowest repeatable • Operator work steps vary observed cycle time • 4 operators TT 90 110 • WIP (as shown) • Line does not meet Pc/t 25 and must run overtime Pc/tMachine Capacity 90% 20 4 4 5 6 3 4 of Pc/t • Op 90 cannot meet Pc/t (see chart) 15 70 3 10Process Stability • Operator cycles fluctuate 2 1 3 2 1 2 1 Our Gemba 5 I I I I up to -30% / + 90% (see chart) 5 2 12 22 • Operator 4 cannot consistently pcs pcs pcs pcs meet Pc/t 10 40 70 90 110 40 10Necessary Number of Operators • 3.2 operators / 4 actual • Operators 1, 2 & 3 are underutilized (see chart) Machines Operators Go & See© Improvement Kata Handbook Current Condition 50 © Lean Management Teachers 13
- 14. Our Improvement Story Q2 Our Current Condition 2 4 3 1 We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision Process: Challenge: TC date: Process: Challenge: TC date: Theme of this TC: Theme of this TC: Step 1: Step 2: Fill in what Step 1: Step 2: Fill in what Fill in current you will keep Fill in current you will keep Current Target the same Current Target the same condition data Condition condition data Condition Condition Condition Step 3: Fill in what Step 3: Fill in what Date you want to change you want to change Takt time: Takt time: Takt time: Takt time: Pc/t: Pc/t: Pc/t: Pc/t: # of Shifts: # of Shifts: # of Shifts: # of Shifts: Overtime (how much): Overtime: Overtime (how much): Overtime: Output / Shift (run chart): Output / Shift: Output / Shift (run chart): Output / Shift: # of Operators: # of Operators: # of Operators: # of Operators: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Describe the process Describe the process Describe the process Describe the process steps, sequence, times: steps, sequence, times: steps, sequence, times: steps, sequence, times: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Other observations about the current pattern: Other observations about the current pattern: -- Example 2 -- All-in-one summary for a manual lineCustomer Demand / Line Pace CURRENT CONDITION Process Metric: Process Metric: • Takt Time = 30 seconds Process • PC/T = 22 seconds Outcome Metric: Outcome Metric: • Gap = 27% Date • Running 2 Shifts + overtime • 10 changeovers per day © Improvement Kata Handbook Target Condition 23 © Improvement Kata Handbook Target Condition 23 40 Range of observed cycle timesOverview • Output cycles vary +/- 109% 35 Lowest repeatable • Operator work steps vary observed cycle time • 4 operators TT 90 110 • WIP (as shown) • Line does not meet Pc/t 25 and must run overtime Pc/tMachine Capacity 90% 20 4 4 5 6 3 4 of Pc/t • Op 90 cannot meet Pc/t (see chart) 15 70 3 10Process Stability • Operator cycles fluctuate 2 1 3 2 1 2 1 Our Gemba 5 I I I I up to -30% / + 90% (see chart) 5 2 12 22 • Operator 4 cannot consistently pcs pcs pcs pcs meet Pc/t 10 40 70 90 110 40 10Necessary Number of Operators • 3.2 operators / 4 actual • Operators 1, 2 & 3 are underutilized (see chart) Machines Operators Go & See© Improvement Kata Handbook Current Condition 50 © Lean Management Teachers 14
- 15. Our Improvement Story Q3 Our obstacles 2 4 3 1 We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision Process: Challenge: TC date: Process: Challenge: TC date: Theme of this TC: Theme of this TC: Step 1: Step 2: Fill in what Step 1: Step 2: Fill in what Fill in current you will keep Fill in current you will keep Current Target the same Current Target the same condition data Condition condition data Condition Condition Condition Step 3: Fill in what Step 3: Fill in what Date you want to change you want to change Takt time: Takt time: Takt time: Takt time: Pc/t: Pc/t: Pc/t: Pc/t: # of Shifts: # of Shifts: # of Shifts: # of Shifts: Overtime (how much): Overtime: Overtime (how much): Overtime: Output / Shift (run chart): Output / Shift: Output / Shift (run chart): Output / Shift: # of Operators: # of Operators: # of Operators: # of Operators: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Describe the process Describe the process Describe the process Describe the process steps, sequence, times: steps, sequence, times: steps, sequence, times: steps, sequence, times: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Other observations about the current pattern: Other observations about the current pattern: -- Example 2 -- All-in-one summary for a manual lineCustomer Demand / Line Pace CURRENT CONDITION Process Metric: Process Metric: • Takt Time = 30 seconds Process • PC/T = 22 seconds Outcome Metric: Outcome Metric: • Gap = 27% Date • Running 2 Shifts + overtime • 10 changeovers per day © Improvement Kata Handbook Target Condition 23 © Improvement Kata Handbook Target Condition 23 40 Range of observed cycle timesOverview • Output cycles vary +/- 109% 35 Lowest repeatable • Operator work steps vary observed cycle time • 4 operators TT 90 110 • WIP (as shown) • Line does not meet Pc/t 25 and must run overtime Pc/tMachine Capacity 90% 20 4 4 5 6 3 4 of Pc/t • Op 90 cannot meet Pc/t (see chart) 15 70 3 10Process Stability • Operator cycles fluctuate 2 1 3 2 1 2 1 Our Gemba 5 I I I I up to -30% / + 90% (see chart) 5 2 12 22 • Operator 4 cannot consistently pcs pcs pcs pcs meet Pc/t 10 40 70 90 110 40 10Necessary Number of Operators • 3.2 operators / 4 actual • Operators 1, 2 & 3 are underutilized (see chart) Machines Operators Go & See© Improvement Kata Handbook Current Condition 50 © Lean Management Teachers 15
- 16. Our Improvement Story Our reflection 2 4 3 1 We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision Process: Challenge: TC date: Process: Challenge: TC date: Theme of this TC: Theme of this TC: Step 1: Step 2: Fill in what Step 1: Step 2: Fill in what Fill in current you will keep Fill in current you will keep condition data Current Condition Reflect Step 3: Fill in what Target Condition on the Last Step Taken the same condition data Current Condition Target Condition the same Step 3: Fill in what Date donʼt Because youchange actually know you want to you want to change Takt time: Takt time: Takt time: Takt time: Pc/t: Pc/t: what the result of a step will be! Pc/t: Pc/t: # of Shifts: # of Shifts: # of Shifts: # of Shifts: Overtime (how much): Overtime: Overtime (how much): Overtime: Output / Shift (run chart): Output / Shift: 1) What was your last step? Output / Shift (run chart): Output / Shift: # of Operators: # of Operators: 2) What actually happened? # of Operators: # of Operators: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Describe the process steps, sequence, times: Describe the process steps, sequence, times: 3) What did you learn? Describe the process steps, sequence, times: Describe the process steps, sequence, times: Exit cycle fluctuation %: ----------------------------> Return Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Other observations about the current pattern: Other observations about the current pattern: -- Example 2 -- All-in-one summary for a manual lineCustomer Demand / Line Pace CURRENT CONDITION Process Metric: Process Metric: • Takt Time = 30 seconds Process • PC/T = 22 seconds Outcome Metric: Outcome Metric: • Gap = 27% Date • Running 2 Shifts + overtime • 10 changeovers per day © Improvement Kata Handbook Target Condition 23 © Improvement Kata Handbook Target Condition 23 40 Range of observed cycle timesOverview • Output cycles vary +/- 109% 35 Lowest repeatable • Operator work steps vary observed cycle time • 4 operators TT 90 110 • WIP (as shown) • Line does not meet Pc/t 25 and must run overtime Pc/tMachine Capacity 90% 20 4 4 5 6 3 4 of Pc/t • Op 90 cannot meet Pc/t (see chart) 15 70 3 10Process Stability • Operator cycles fluctuate 2 1 3 2 1 2 1 Our Gemba 5 I I I I up to -30% / + 90% (see chart) 5 2 12 22 • Operator 4 cannot consistently pcs pcs pcs pcs meet Pc/t 10 40 70 90 110 40 10Necessary Number of Operators • 3.2 operators / 4 actual • Operators 1, 2 & 3 are underutilized (see chart) Machines Operators Go & See© Improvement Kata Handbook Current Condition 50 © Lean Management Teachers 16
- 17. Our Improvement Story Q4 Our next step 2 4 3 1 We were Now we are here, We want Challenge here using PDCA to overcome obstacles to be here & Vision Process: Challenge: TC date: Process: Challenge: TC date: Theme of this TC: Theme of this TC: Step 1: Step 2: Fill in what Step 1: Step 2: Fill in what Fill in current you will keep Fill in current you will keep Current Target the same Current Target the same condition data Condition condition data Condition Condition Condition Step 3: Fill in what Step 3: Fill in what Date you want to change you want to change Takt time: Takt time: Takt time: Takt time: Pc/t: Pc/t: Pc/t: Pc/t: # of Shifts: # of Shifts: # of Shifts: # of Shifts: Overtime (how much): Overtime: Overtime (how much): Overtime: Output / Shift (run chart): Output / Shift: Output / Shift (run chart): Output / Shift: # of Operators: # of Operators: # of Operators: # of Operators: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Where 1x1, where WIP: Describe the process Describe the process Describe the process Describe the process steps, sequence, times: steps, sequence, times: steps, sequence, times: steps, sequence, times: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Exit cycle fluctuation %: Other observations about the current pattern: Other observations about the current pattern: -- Example 2 -- All-in-one summary for a manual lineCustomer Demand / Line Pace CURRENT CONDITION Process Metric: Process Metric: • Takt Time = 30 seconds Process • PC/T = 22 seconds Outcome Metric: Outcome Metric: • Gap = 27% Date • Running 2 Shifts + overtime • 10 changeovers per day © Improvement Kata Handbook Target Condition 23 © Improvement Kata Handbook Target Condition 23 40 Range of observed cycle timesOverview • Output cycles vary +/- 109% 35 Lowest repeatable • Operator work steps vary observed cycle time • 4 operators TT 90 110 • WIP (as shown) • Line does not meet Pc/t 25 and must run overtime Pc/tMachine Capacity 90% 20 4 4 5 6 3 4 of Pc/t • Op 90 cannot meet Pc/t (see chart) 15 70 3 10Process Stability • Operator cycles fluctuate 2 1 3 2 1 2 1 Our Gemba 5 I I I I up to -30% / + 90% (see chart) 5 2 12 22 • Operator 4 cannot consistently pcs pcs pcs pcs meet Pc/t 10 40 70 90 110 40 10Necessary Number of Operators • 3.2 operators / 4 actual • Operators 1, 2 & 3 are underutilized (see chart) Machines Operators Go & See© Improvement Kata Handbook Current Condition 50 © Lean Management Teachers 17

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