NG BB 50 Rapid Improvement Event
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NG BB 50 Rapid Improvement Event Presentation Transcript

  • 1. UNCLASSIFIED / FOUO National Guard Black Belt Training Module 50 Rapid Improvement Event (RIE) UNCLASSIFIED / FOUO
  • 2. UNCLASSIFIED / FOUOCPI Roadmap – Improve 8-STEP PROCESS 6. See 1.Validate 2. Identify 3. Set 4. Determine 5. Develop 7. Confirm 8. Standardize Counter- the Performance Improvement Root Counter- Results Successful Measures Problem Gaps Targets Cause Measures & Process Processes Through Define Measure Analyze Improve Control TOOLS ACTIVITIES •Brainstorming • Develop Potential Solutions •Replenishment Pull/Kanban • Develop Evaluation Criteria •Stocking Strategy • Select Best Solutions •Process Flow Improvement • Develop Future State Process Map(s) •Process Balancing • Develop Pilot Plan •Standard Work • Pilot Solution •Quick Change Over • Develop Full Scale Action/ •Design of Experiments (DOE) Implementation Plan •Solution Selection Matrix • Complete Improve Gate •„To-Be‟ Process Mapping •Poka-Yoke •6S Visual Mgt •RIE Note: Activities and tools vary by project. Lists provided here are not necessarily all-inclusive. UNCLASSIFIED / FOUO 2
  • 3. UNCLASSIFIED / FOUO Learning Objectives  Identify opportunities for quick improvements, whether „Just Do Its‟ or RIE improvements  Learn the conditions that may lead to a quick improvement  Discuss the RIE methodology for quick improvement  Learn the difference between a project „Just Do It‟ and a RIE UNCLASSIFIED / FOUO 3
  • 4. UNCLASSIFIED / FOUO Quick Improvement Method  The CPI training focuses on a disciplined roadmap to Process Improvement (8-Steps or DMAIC)  The key to effect process improvement is successful completion of the Measurement and Analysis phases  They set the stage for Improvement  However:  Opportunities may be identified early in the project that do not warrant extensive analysis  „Just Do Its‟ or „Quick Wins‟ bypass Analyze and go straight to Improve Phase  RIE improvements still follow the DMAIC/8-Step format but the Define, Measure, and Analyze portions are accelerated UNCLASSIFIED / FOUO 4
  • 5. UNCLASSIFIED / FOUO Just Do It (Quick Win) UNCLASSIFIED / FOUO 5
  • 6. UNCLASSIFIED / FOUO Just Do It  Often we are able to find some opportunities for immediate improvement early in the project using basic tools  Process map  Pareto chart  Fishbone Diagram  Metric Implementation (Hawthorne effect) Productivity Y Process Map Pareto Chart Cause & Effect UNCLASSIFIED / FOUO 6
  • 7. UNCLASSIFIED / FOUO Just Do It  When we find these opportunities there is no need to wait months for implementation  We should implement change as soon as possible to begin reaping the benefits  We by-pass the Analyze phase and move straight to Improve $$ Define Measure Analyze Improve Control UNCLASSIFIED / FOUO 7
  • 8. UNCLASSIFIED / FOUO Just Do It Improvement Criteria  Minimal or no capital expenditure  Low risk  Narrow scope  Buy-in to solutions by all stakeholders  Certainty the change will generate a positive impact  Improvements may be implemented quickly (within 1- 2 weeks)  The project team has the authority to implement the desired changes UNCLASSIFIED / FOUO 8
  • 9. UNCLASSIFIED / FOUO Just Do It - Examples  Process Step Elimination  Procedure Change  Safety Stock Elimination (Just in Case Inventory)  Communication Improvement  Supplier Price Reduction  Part Substitution  Training on Best Practices  Error Proof a Process Step  Process Balancing / Layout UNCLASSIFIED / FOUO 9
  • 10. UNCLASSIFIED / FOUO Just Do It - CAUTIONS  Risk assessment must be an essential part of the „Just Do It‟ decision process  What are the potential „Just Do It‟ impacts on:  Customers/Suppliers  Other functional areas  Cost/Benefit analysis  Other teams‟ efforts UNCLASSIFIED / FOUO 10
  • 11. UNCLASSIFIED / FOUO Quick Improvement Control Plans  Quick improvements, whether „Just Do It‟ or Rapid Improvement Events, must have implemented Control Plans in place before being considered complete  It is desirable to implement improvements as soon as possible but implementation without control can be worse than no implementation at all  See the Control Plan Module for Control Plan implementation and details UNCLASSIFIED / FOUO 11
  • 12. UNCLASSIFIED / FOUO Rapid Improvement Events UNCLASSIFIED / FOUO 12
  • 13. UNCLASSIFIED / FOUO Rapid Improvement Event Facilitation  RIE is the application of continuous improvement to a specific, targeted process objective  RIE assembles cross-functional teams aimed at improving a process or problem identified within a specific area UNCLASSIFIED / FOUO 13
  • 14. UNCLASSIFIED / FOUO What is an RIE?  An RIE is an Event  Defined duration (clear start & end point)  Where Improvements are made  Changes happen during event  In a Rapid fashion  Event duration is short & changes happen fast UNCLASSIFIED / FOUO 14 14
  • 15. UNCLASSIFIED / FOUO Important Considerations  Events last from 3 to 5 days and during this period production may be negatively affected  This requires planning to avoid affecting customer deliveries  Anticipate a learning curve on the changes implemented  Document as the event happens – for example, complete Value Stream Maps and Standardized Worksheets during the event UNCLASSIFIED / FOUO 15
  • 16. UNCLASSIFIED / FOUO RIE Facilitation Is and Is Not RIE is: RIE is not:  A tactical facilitation  A tool to be used to method for reaching reduce headcount strategic goals  A strategic approach  A way to do pet projects  The involvement of all  Just an expert activity stakeholders  Well planned out  A haphazard event UNCLASSIFIED / FOUO 16
  • 17. UNCLASSIFIED / FOUO When to Use Rapid Improvement Events  When obvious waste sources have been identified As the result of Process Mapping,  When the scope and boundaries of a work area tour, data collection, etc., problem are clearly defined and obvious sources of understood instability and waste are identified  When implementation risk is minimal Examples:  When results are needed immediately - Standardization (SOPs), 6S, Generic i.e., capacity constraints, setup Pull, Setup reduction, acute quality problems, Reduction safety/ergonomic issues  In the early stages of a project to gain momentum and build credibility UNCLASSIFIED / FOUO 17
  • 18. UNCLASSIFIED / FOUO RIE Facilitation Approach  Team is 5 days full-time vs. 4 months part-time  Actual team hours may be similar  Resources are dedicated  100% dedicated for the event (5 days)  Scope is completed and problem is identified going in  Team does not have time for scope assessment  Basic data is gathered  Be ready to implement immediately  Complete as much as possible the week of event  May use tribal knowledge vs. detailed analysis  Solution may be known but historically not listened to  Allow 30-day follow-up on action items  Items that cannot be finished that week UNCLASSIFIED / FOUO 18
  • 19. UNCLASSIFIED / FOUO RIE Approach  RIE is a vehicle to implement „Quick Wins‟ A. Pre-Event Prep: Identify and plan narrow scope events B. RIE: Implement do-now quick hit solutions during the RIE C. Follow-up Action Items: RIE activity typically ends 30 days following RIE  The RIE approach follows the DMAIC/8-Step process Typical RIE Timeline Pre-Event RIE Event Follow-up Prep (3-5 days) (15-30 days) (3-5 days) UNCLASSIFIED / FOUO 19
  • 20. UNCLASSIFIED / FOUO RIE Follows the DMAIC/8-Step Structure Define (Prep Week)  Clearly define the RIE objective  Pre-Event prep: Select team members, perform logistics, notifications, data collections, and prepare training Measure (Prep Week and Monday of Event)  Validate the value-stream map of the process. Complete a resource flow layout for all operations or tasks if necessary (people, paper, material, information)  Carefully observe, then collect needed metrics for tasks or steps in the selected process UNCLASSIFIED / FOUO 20
  • 21. UNCLASSIFIED / FOUO RIE Follows the DMAIC/8-Step Structure  Analyze (Tuesday-Wednesday)  Quickly validate root causes and identify/review sources of waste  Review waste elimination techniques, then brainstorm process improvements for eliminating non-value added tasks (CVA and NVA-R as well) and reducing variation  Improve (Wednesday-Friday)  Create action item list to accomplish improvements  Implement process improvements, train employees, then test, fine-tune, and ensure the process is capable  Control (Thursday-Friday)  Create Standard Operating Procedures to document and sustain improvements  Present results to Management Team, complete follow-up, monitor results over time UNCLASSIFIED / FOUO 21
  • 22. UNCLASSIFIED / FOUO RIE Preparation Preparation Phase (1-2 Weeks before start of event)  Data Collection/Analysis  Resources Alerted  Team Selection/Notified  Create “Specialized” Training  Scope Identified  Equipment  $$ Savings Determined  Logistics Arranged  Process Map UNCLASSIFIED / FOUO 22
  • 23. UNCLASSIFIED / FOUO “Specialized” Training for Team  The entire team should be trained to use the following tools:  6s Work place organization  Time study  Takt time  Standard work layouts  Standard work combination sheets  Spaghetti diagrams  Run charts  Value add  Process capability UNCLASSIFIED / FOUO 23
  • 24. UNCLASSIFIED / FOUO Logistics  Meeting room near work area  Quiet  Work spaces for individuals and team meetings  Tools needed for team work  Flip charts, masking tape, and markers  Computer, projector, screen  White board  Telephone  Typical office equipment  Post Its!!! UNCLASSIFIED / FOUO 24
  • 25. UNCLASSIFIED / FOUO General RIE Week Structure Area Discovery Brainstormed Ideas Issue List Goal Team Training Cause & Effect 5.0 4.5 3 4.0 9 3.5 8 3.0 67 What Who When Status 2.5 Benefit 2.0 4 1 1.5 5 10 2 1.0 .5 .5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 Action Items Final Implementation Effort Presentation UNCLASSIFIED / FOUO 25
  • 26. UNCLASSIFIED / FOUO Typical Timeline Monday Tuesday Wednesday Thursday Friday 8AM Future State Des Mid-Week Review Finalize Future State Measure Implement Complete Training (Present State Future State Des Finalize Improvements on Std Work Analysis) 10AM Pre-Event Perform Process Prep Participant Training Implement Tweak Design Improvements Final Presentation Analyze 12PM Lunch Lunch Lunch Lunch Lunch & Celebration RIE Kickoff Lean/RIE Training Create and 2PM Analyze Implement Standard Specialized Training Brainstorm Ideas Implement Work Improvements Idea Effort/Impact Measure Future Perform Process Idea Prioritization State Participant Training Future State Design Calculate Actual Tweak Design 4PM Benefits Measure (Present State Analysis) Process Part Design Create Final Review Presentation 6PM UNCLASSIFIED / FOUO 26
  • 27. UNCLASSIFIED / FOUO RIE Schedule - Example Mon, Sep 9 Tue, Sep 10 Wed, Sep 11 Thu, Sep 12 Fri, Sep 13 7:00 AM Review plan for the day Review plan for the day Review plan for the day Review plan for the day 7:30 AM 8:00 AM 8:30 AM Area Observations 9:00 AM Continue Continue 9:30 AM Brainsorm Solutions implementation implementation 10:00 AM Guest Speaker, Intro & Prepare presentation 10:30 AM Training Area Observations 11:00 AM 11:30 AM 12:00 PM Lunch Lunch & status review Lunch & status review Lunch & status review Lunch & status review 12:30 PM 1:00 PM Problems seen Affinitize list of possible Presentation & Define & assign roles 1:30 PM Fishbone diagram solutions Questions Area Discovery 2:00 PM Complete Effort / Impact 2:30 PM Matrix Continue 3:00 PM Assign Action Items implementation 3:30 PM Cause & effect Prepare presentation Area Discovery 4:00 PM Begin Implementation 4:30 PM 5:00 PM Capture observations & ideas Status review & updates Status review & updates Status review & updates 5:30 PM 6:00 PM Time to go home Time to go home Time to go home Time to go home UNCLASSIFIED / FOUO 27
  • 28. UNCLASSIFIED / FOUO RIE Team Rules  Be open to change  Maintain a positive attitude  Never leave disagreements unspoken  We‟re not interested in assigning blame - only in creating solutions  Practice mutual respect  Treat others as you want to treated  One person, one vote – position doesn‟t matter  The only stupid questions are the ones not asked  Have fun  Understand the process and…JUST DO IT! UNCLASSIFIED / FOUO 28
  • 29. UNCLASSIFIED / FOUO Facilitation Keys  Keep Team Busy!  Tendency for emails, voicemails, etc.  Event will be stressful  Forcefully stay on track  Be a part of scope and team selection if possible  Plant seeds but don‟t overpower the team with your ideas  Give something back to area personnel UNCLASSIFIED / FOUO 29
  • 30. UNCLASSIFIED / FOUO RIE Detail Schedule Monday or Before  Team Training  What is a RIE?  Project and Goal Background  Present Data/Burning Platform  Specialized Training Geared Toward Project Goal  Discovery  Team Spends Afternoon in Project Area  Gather Insights from Personnel  Observe Issues/Conduct Studies  Keep Detailed Notes UNCLASSIFIED / FOUO 30
  • 31. UNCLASSIFIED / FOUO Discovery Phase  The team “Discovery” is the most important part of the RIE  It is during the Discovery that the team identifies opportunity for improvement  Keys to Discovery success:  Is a rotation schedule needed?  Write everything down  Are more backup data needed?  Keep everyone busy  Expect long hours UNCLASSIFIED / FOUO 31
  • 32. UNCLASSIFIED / FOUO Capture/Brainstorm Ideas UNCLASSIFIED / FOUO 32
  • 33. UNCLASSIFIED / FOUO Toolset Used During RIE  Any tool may be used to aid the team during a RIE from a Process Map to a Designed Experiment  Bottom line is you use any tool that is needed!  Pareto  C & E matrix  Fishbone  4 Step Set Up Reduction  Process map  Personnel/Skillset Matrix  Spaghetti Diagram  Brainstorming  Takt Time  Affinity Diagram  NVA Analysis  Prioritization Tools  Time Studies  Pilot Plans UNCLASSIFIED / FOUO 33
  • 34. UNCLASSIFIED / FOUO RIE Toolset Resource Flow FORSCOM Layout Form 107-R Mob Form PA Form 106(“Spaghetti Flow”) SOLDIER / FAMILY INFORMATION SOLDIER / FAMILY INFORMATION Privacy Act Statement Authority: Title 10, United State Code, Section 3013 Privacy Act Statement To identify your significant others: parents, spouse, children, friends, employer, etc. information gathered may be Principal Purpose: Authority: Title 10, United State Code, Section 3013 informational letters from the usedCommanding General and assist in the development of appropriate outreach through to produce SOLDIER / FAMILY INFORMATION SOLDIER / FAMILY INFORMATION Principal Purpose: To identify your significant others: parents, spouse, children, friends, employer, etc. information gathered may be Family Readiness Group (FRG) activities and services to the persons you list. All individuals identified are eligible to participate in informational letters from the usedCommanding General and assist in the development of appropriate outreach through to produce and receive informationthe FRG assist you in having a successful deployment should you be mobilized and deployed. that will Family Readiness Group (FRG) activities and services to the persons you list. All individuals identified are eligible to participateinformation you provide may be disclosed to members of DoD who have an official need for the information in Privacy Act Statement Privacy Act Statement Any in Routine Uses: the FRG and receive information that will assist you in having a successful deployment should you be mobilized and deployed. ce of their duties, including the Chaplains, Family Readiness personnel and the Operational Stress Control team of the the performan Authority: Title 10, United State Code, Section 3013 Authority: Title 10, United State Code, Section 3013 Routine Uses: you provide may be disclosed to members of DoD who have an official need for the information in Any information st RRC, as well as to: (a) 81 Federal, State, local or foreign law enforcement purposes, (b) Federal, State or local agencies that maintai n Principal Purpose: To identify your significant others: parents, spouse, children, friends, employer, etc. information gathered may be Principal Purpose: To identify your significant others: parents, spouse, children, friends, employer, etc. information gathered may be the performan ce of their duties, including the Chaplains, Family Readiness personnel and the Operational Stress Control team of the civil, criminal, or other relevant enforcement information to obtain data relevant to an Army decision, (c) other federal agencies in informational letters from the usedCommanding General and assist in the development of appropriate outreach through to produce informational letters from the usedCommanding General and assist in the development of appropriate outreach through to produce st 81 RRC, as well as to: (a) Federal, State, local or foreign law enforcement purposes, (b) Federal, State or local agencies that connection with hiring, security clearances, andin n maintai onal offices investigation of an employee, or the letting of contract, (d) Congressi Family Readiness Group (FRG) activities and services to the persons you list. All individuals identified are eligible to participate in Family Readiness Group (FRG) activities and services to the persons you list. All individuals identified are eligible to participate in civil, criminal, or other relevant enforcement information to obtain data relevant to an Army decision, (c) other federal agencies in response to Congressional inquiries, and (e) OMB for the review of private relief legislation. the FRG and receive information that will assist you in having a successful deployment should you be mobilized and deployed. the FRG and receive information that will assist you in having a successful deployment should you be mobilized and deployed. connection with hiring,in onal offices security clearances, and investigation of an employee, or the letting of contract, (d) Congressi Routine Uses: you provide may be disclosed to members of DoD who have an official need for the information in Any information Routine Uses: you provide may be disclosed to members of DoD who have an official need for the information in Any information response to Congressional inquiries, and (e) OMB for the review of private relief legislation. the performan ce of their duties, including the Chaplains, Family Readiness personnel and the Operational Stress Control team of the the performan ce of their duties, including the Chaplains, Family Readiness personnel and the Operational Stress Control team of the SOLDIER INFORMATION: st 81 RRC, as well as to: (a) Federal, State, local or foreign law enforcement purposes, (b) Federal, State or local agencies that maintai n st 81 RRC, as well as to: (a) Federal, State, local or foreign law enforcement purposes, (b) Federal, State or local agencies that maintai n civil, criminal, or other relevant enforcement information to obtain data relevant to an Army decision, (c) other federal agencies in civil, criminal, or other relevant enforcement information to obtain data relevant to an Army decision, (c) other federal agencies in SOLDIER INFORMATION: connection with hiring,in onal offices security clearances, and investigation of an employee, or the letting of contract, (d) Congressi connection with hiring, security clearances, and investigation of an employee, or the letting of contract, (d) Congressi onal offices in NAME:______________________________ MI___ _LAST __ FIRST___________________ response to Congressional inquiries, and (e) OMB for the review of private relief legislation. response to Congressional inquiries, and (e) OMB for the review of private relief legislation. NAME:______________________________ MI___ _LAST __ FIRST___________________ SSN________ -_______ (MM/DD/YYYY): ____/____/____ _ DOB - __________ SOLDIER INFORMATION: SOLDIER INFORMATION: SSN________ ____________ - -______ (MM/DD/YYYY): ____/____/____ DOB Marital Status: Single o o D Married o Separated o Widowed o Single Parent o ivorced Date of Marriage: ______________ NAME:______________________________ MI___ _LAST __ FIRST___________________ NAME: FIRST___________________ MI___ _LAST __ ______________________________ Marital Status: Single o o D Married o Separated o Widowed o Single Parent o ivorced Date of Marriage: ______________ HOME PHONE: _______________________ ________ CELL PHONE: ______________________ SSN________ ____________ - -______ (MM/DD/YYYY): ____/____/____ DOB SSN________ ____________ --______ (MM/DD/YYYY): ____/____/____ DOB Your AKO e m - ail Account HOME PHONE: _______________________ ________ CELL PHONE: ______________________ Marital Status: Single o o D Married o Separated o Widowed o Single Parent o ivorced Marital Status: Single o o D Married o Separated o Widowed o Single Parent o ivorced WORK PHONE: ______________________ _______________________@ us.army.mil Your AKO e m - ail Account Date of Marriage: ______________ Date of Marriage: ______________ HOME ADDRESS: ____________________ _______________________________________________ WORK PHONE: ______________________ _______________________@ us.army.mil CITY_______________________ _STATE ZIP Code ________________ ___________ HOME ADDRESS: ____________________ _______________________________________________ HOME PHONE: _______________________ ________ CELL PHONE: ______________________ HOME PHONE: _______________________ ________ CELL PHONE: ______________________ CITY_______________________ _STATE ZIP Code ________________ ___________ Your AKO e m - ail Account Your AKO e m - ail Account Current Unit: _________________________ Leadership Role: _____________________ ____ WORK PHONE: ______________________ _______________________@ us.army.mil WORK PHONE: ______________________ _______________________@ us.army.mil Current Unit: _________________________ Leadership Role: _____________________ ____ Are being cross you - eveled: l HOME ADDRESS: ____________________ _______________________________________________ HOME ADDRESS: ____________________ _______________________________________________ 211 CITY_______________________ _STATE ZIP Code ________________ ___________ CITY_______________________ _ STATE ZIP Code ________________ ___________ Gaining unit and / or RRC: _________________________ RANK: __________________ Are being cross you - eveled: l 211 Gaining unit and / or RRC: _________________________ RANK: __________________ Current Unit: _________________________ Leadership Role: _____________________ ____ Current Unit: _________________________ Leadership Role: _____________________ ____ ___ Does F amily Member have a signed DD 1172? ____ Is Family Member enrolled in DEERS? ___ DDuty ID Card? have Does Family Member requires special oes Family Member ___ an Dependent ___ Does F amily Member have a signed DD 1172? ____ Is Family Member enrolled in DEERS? Are being cross you - eveled: l Are being cross you - eveled: l assistance? ___ DDuty ID Card? have Does Family Member requires special oes Family Member ___ an Dependent 211 Gaining unit and / or RRC: _________________________ RANK: __________________ 211 Gaining unit and / or RRC: _________________________ RANK: __________________ assistance? FAMILY MEMBERS: this box.) (You must complete ___ Does F amily Member have a signed DD 1172? ____ Is Family Member enrolled in DEERS? ___ Does F amily Member have a signed DD 1172? ____ Is Family Member enrolled in DEERS? FAMILY MEMBERS: this box.) (You must complete Provide family member, loved onefor significant al closest you consider your the following information or the individu ___ DDuty ID Card? have Does Family Member requires special oes Family Member ___ an Dependent ___ DDuty ID Card? have Does Family Member requires special oes Family Member ___ an Dependent other: Names listed below will be included on your FRG Unit Telephone Tree as your Primary Contact. assistance? assistance? Indicates flow Provide family member, loved onefor significant al closest you consider your the following information or the individu other: Names listed below will be included on your FRG Unit Telephone Tree as your Primary Contact. NAME: ___________________ FIRST___________________ MI____ LAST_____________ FAMILY MEMBERS: this box.) (You must complete FAMILY must complete this box.) (You MEMBERS: NAME: ___________________ FIRST___________________ MI____ LAST_____________ RELATIONSHIP: o Child o Significant Other o Other o Provide family member, loved onefor significant al closest you consider your the following information or the individu Providefamily member, loved one forsignificant al closest you consider your the following information or the individu Spouse o o Father Mother Date of Marriage:___________________ DOB: __________ Age: _________ other: Names listed below will be included on your FRG Unit Telephone Tree as your Primary Contact. other: Names listed below will be included on your FRG Unit Telephone Tree as your Primary Contact. RELATIONSHIP: o Child o Significant Other o Other o Spouse o o Father Mother Date of Marriage:___________________ DOB: __________ Age: _________ NAME: ___________________ FIRST___________________ MI____ LAST_____________ NAME: ___________________ FIRST___________________ MI____ LAST_____________ Foreign address: ______________ mail -Language? If yes, which: _______________________ e __________ Foreign address: ______________ mail -Language? If yes, which: _______________________ e __________ RELATIONSHIP: o Child o Significant Other o Other o Spouse o o Father Mother RELATIONSHIP: o Child o Significant Other o Other o Spouse oo Father Mother WORK HOME PHONE: PHONE: ______________________ _________________ Date of Marriage:___________________ DOB: __________ Age: _________ Date of Marriage:___________________ DOB: __________ Age: _________ MAILING ADDRESS: __________________ ________________________________ _____ PHONE: CELL WORK HOME PHONE: PHONE: ______________________ _________________ CITY_______________________ STATE ________ ZIP Code _______________________ MAILING ADDRESS: __________________ ________________________________ _____ PHONE: CELL Foreign address: ______________ mail -Language? If yes, which: _______________________ e __________ Foreignaddress: ______________ - Language? If yes, which: _______________________ e mail__________ CITY_______________________ STATE ________ ZIP Code _______________________  Will Family Member be at this address during Soldier Mobilization / Deployment? Yes__ No__ WORK HOME PHONE: PHONE: ______________________ _________________ WORKHOME PHONE: PHONE: ______________________ _________________ rovide new address: If no, p  Will Family Member be at this address during Soldier Mobilization / Deployment? Yes__ No__ MAILING ADDRESS: __________________ ________________________________ _____ PHONE: CELL MAILING ADDRESS: __________________ ________________________________ _____ PHONE: CELL rovide new address: If no, p CITY_______________________ STATE ________ ZIP Code _______________________ CITY_______________________ STATE ________ ZIP Code _______________________ MAILING ADDRESS : ________________________________________________________ MAILING ADDRESS : ________________________________________________________  Will Family Member be at this address during Soldier Mobilization / Deployment? Yes__ No__  Will Family Member be at this address during Soldier Mobilization / Deployment? Yes__ No__ CITY_______________________ STATE ________ ZIP Code _______________________ rovide new address: If no, p rovide new address: If no, p CITY_______________________ STATE ________ ZIP Code _______________________ MAILING ADDRESS : ________________________________________________________ MAILING ADDRESS : ________________________________________________________ CITY_______________________ STATE ________ ZIP Code _______________________ CITY_______________________ STATE ________ ZIP Code _______________________ Soldier Info Contact Info Family Info Indicates an in-box or outbox where work (forms/information) waits to be worked on or transferred UNCLASSIFIED / FOUO 34
  • 35. UNCLASSIFIED / FOUO RIE Tool Example Process: Sub-Process: Date: Date: Observer Family Readiness Group Contact AFRP Contact List Best Observed Cycles: Repeatable Standard Task Description 1 2 3 4 5 6 7 8 9 10 Time Deviation Remarks Clock 9 7 11 12 10 10 13 10 11 10 Complete FRG Forms Elapsed 9 7 11 12 10 10 13 10 11 10 10 1.6 Too Many Forms Clock 13 15 11 16 17 15 16 15 14 13 Input FRG Forms into Website is too AFRP.org Elapsed 13 15 11 16 17 15 16 15 14 13 15 1.8 slow How do w e Clock 7 7 7 7 7 7 7 7 7 7 maintain accurate Review Family Member info if something Contact Info Elapsed 10 12 18 13 14 12 13 12 11 10 7 0.0 chnages Clock 8 7 10 12 11 10 10 9 8 7 Call Family Member Elapsed 8 9 8 5 5 12 13 11 9 7 10 1.7 Clock 2 4 5 3 3 4 3 5 2 3 Update AFRP.org contact data Elapsed 2 4 5 4 4 4 3 5 2 3 3 1.1 Clock Elapsed 45 Avg UNCLASSIFIED / FOUO 35
  • 36. UNCLASSIFIED / FOUO RIE Tool Example Family Readiness Group Form 107-R Family Contact Need to reduce to meet customer Takt Tim e = 13 m in demand! 20 Task Time (minutes) 15 10 5 0 Complete Input Forms Store Use Use Call Family Forms(107- Hardcopy Database Hardcopy R) Task # CVA Time NVA-R Time NVA Time UNCLASSIFIED / FOUO 36
  • 37. UNCLASSIFIED / FOUO RIE Tool Example As a team, determine which activities are non-value added UNCLASSIFIED / FOUO 37
  • 38. UNCLASSIFIED / FOUO Typical RIE Schedule (Cont.) Tuesday  Area Discovery (Cont.)  Team Spends Morning in Project Area  Gather Insights from Personnel  Observe Issues/Conduct Studies  Back to Room to Brainstorm Issues  What was learned?  Write down ideas  Evaluate Studies UNCLASSIFIED / FOUO 38
  • 39. UNCLASSIFIED / FOUO Typical RIE Schedule (Cont.) Wednesday  Brainstorm Issues  Capture Ideas/Solutions  Evaluate Studies  Reduce and Prioritize Ideas  Affinitize Ideas/Solutions  Utilize Effort vs. Impact Matrix  Assign Numbers Based on Effort and Impact  Midweek Status Meeting  Vector check / Milestone review UNCLASSIFIED / FOUO 39
  • 40. UNCLASSIFIED / FOUO Quantify Ideas by Impact on Goal Quantify each idea by contribution to problem UNCLASSIFIED / FOUO 40
  • 41. UNCLASSIFIED / FOUO Brainstorm, Affinitize, Prioritize Improvements 5.0  Take each brainstormed 4.5 4.0 9 3 idea and have the team 3.5 67 8 assign an effort and an impact to each 3.0 Benefit 2.5 4 2.0  Transferthis information to 1 1.5 10 2 5 a spreadsheet to sort the 1.0 .5 .5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 ideas based on Highest Effort Impact and Lowest Effort  Thisbecomes the teams Create ranked list of improvements activity and priority list UNCLASSIFIED / FOUO 41
  • 42. UNCLASSIFIED / FOUO Create Effort/Impact Priority List By quantifying the effort and impact and sorting in a spreadsheet, this may be used as the action item list Quantified Impact on Goal Final Ranking Priority Avg Avg Final Solution Responsible Action Plan Impact Effort Ranking Align Modified Table of Equipment (MTOE) in Property 8.0 1.1 4.6 Nate, Mary, Ed Call Help Desk to clean up MTOE by MTOE Book and Unit Supply E Recheck Unit Identification Code tree on a regular Francis, Mary, 4.0 1.3 2.6 Create reminder to check basis(annually) and as new units are assinged Gary Property Book Officers (PBO) and supply sergeants to 3.0 1.3 2.1 Dave Sw . Supply Level Mgmt. System to communicate pull status at least 2 times a week. PBOs should only order class 2,4 and 7 and allow the 3.0 1.0 2.0 Gary Quick fix w ill be procedural change. supply sergeants to process their own requests UNCLASSIFIED / FOUO 42
  • 43. UNCLASSIFIED / FOUO Mid-Week Review Mid-Week Review Meeting:  Purpose: (Buy-In and Decisions) To review with local management team the analysis findings and the proposed RIE activities for implementation; to address any obstacles impacting the team‟s implementation plan; gain understanding and agreement from Management to proceed with proposed RIE implementation.  Responsibility for Conducting the Meeting: RIE Project Team Leader  Frequency: For Projects beginning Monday afternoon, this meeting will occur early Wednesday afternoon, typically between 1:00 p.m. and 2:30 p.m.  Duration: 30 Minutes  Attendees: RIE Project Team Leader, Key Stakeholders, Sponsor, Process Owner UNCLASSIFIED / FOUO 43
  • 44. UNCLASSIFIED / FOUO Typical RIE Schedule (Cont.) Thursday  Implement Solutions  Each team member acts on their assignments  Build future state  Pilot or test new ideas  Review Progress  AM review of assignments  Noon review of progress  PM review of progress UNCLASSIFIED / FOUO 44
  • 45. UNCLASSIFIED / FOUO Implementation  Training  Conduct training that week  Communication  Communicate to the area personnel the changes UNCLASSIFIED / FOUO 45
  • 46. UNCLASSIFIED / FOUO Typical RIE Schedule (Cont.) Friday  Implement Solutions  Each team member acts on their assignments  Implement plan  Team Presentation to Management UNCLASSIFIED / FOUO 46
  • 47. UNCLASSIFIED / FOUO RIE Team Final Presentation Purpose  The purpose of the RIE team final presentation is to provide a forum for improvement teams to inform local management of workshop findings and progress  The presentation formalizes expected results and openly and clearly communicates ownership of open action items and result sustainment  The RIE report-out presentation also provides the opportunity for management to publicly congratulate team members for successes and express appreciation for their dedicated teamwork.  The presentation flows to tell the story about how the team progressed from the project area discovery phase to the team follow-up plan.  RIE team members deliver the presentation to the management team UNCLASSIFIED / FOUO 47
  • 48. UNCLASSIFIED / FOUO RIE Team Final Presentation Flow Event Description Info Goal & Objectives Assessment/Analysis • Event Name & Date • Charter (Problem Statement) • Initial findings • Team name • Quantifiable goals (projected) • Before Value-Stream Map • Team Members • Qualitative objectives • Before procedures • Key process issues Standardization Implementation Brainstorming Causes • After/improved process map • RIE storyboards describing • Root cause analysis • New SOPs and examples of what the team implemented • Brainstormed ideas how to sustain • Pictures are key • Effort/Impact outcome Results Follow-Up Parking Lot • Quantifiable (vs. Projected) • Action list team will • Items parked for other • Qualitative (vs. Projected) complete teams /management • Keep to 20 or less items consideration • Management “need helps” • Risks/Issues for success UNCLASSIFIED / FOUO 48
  • 49. UNCLASSIFIED / FOUO Use A3 Project Summary Report for RIE Company: Department: Date: Prepared by: 1. Define the problem situation 3. Action plans to correct problems 2. Problem Analysis 4. Results of Activity 5. Future Steps UNCLASSIFIED / FOUO 49
  • 50. UNCLASSIFIED / FOUO Takeaways Now you should be able to:  Identify opportunities for quick improvements, whether „Just Do Its‟ or RIE improvements  Learn the conditions that may lead to a quick improvement  Discuss and apply the RIE facilitation methodology for quick improvement UNCLASSIFIED / FOUO 50
  • 51. UNCLASSIFIED / FOUO What other comments or questions do you have? UNCLASSIFIED / FOUO 51
  • 52. UNCLASSIFIED / FOUO APPENDIX Preparation and Facilitation UNCLASSIFIED / FOUO 52
  • 53. UNCLASSIFIED / FOUO Training and Facilitation Materials  RIE Facilitation Kit Will Cover:  RIE Schedule and Approach  Pre-Event Preparation  Team Selection  Pre-event Communications/Preparation  Policies and Procedures  Presentation Preparation  Facilitation Tools  Data Collection  Mapping and Measurement  Safety Awareness UNCLASSIFIED / FOUO 53
  • 54. UNCLASSIFIED / FOUO Typical RIE Weekly Schedule Weekly Calendar Pre-w ork 1. Review Scope, Goals, Objectives, and Deliverables With Senior Staff 2. Select Team Leader 2A. Select Team Members 2B. Inform Team Members 3. Gather Data (Demand, Quality, Headcount, WIP, Downtime, Overtime, Safety, Before Pics) 4. Set Meeting Rooms, Food, Develop Team Tool Box 11/27 Monday 1. Kaizen Kickoff (Senior Staff Representative) 2. Kaizen Training (Lean Principles) & Specialized for Project 3. Review Project Scope, Goals (SMART), Deliverables with Team 4. Assign Tasks for Process Observations, Timestudies, 5-S, Spaghetti Charts, Takt Time Chart 5. Train Team Members in Timestudy Basics and Begin Observation and Data Gathering 11/28 Tuesday 1. Complete Present State Analysis Using All Appropriate Data 2. Brainstorm Based on Goals & Objectives, Ergonomics, Safety, & Waste Elimination 3. Create Future State Analysis and Action Plan 4. Team Lead and Consultant Review FSA With Senior Staff 5 Launch Sub-Teams and Complete Plan 11/29 Wednesday 1. Complete Action Plan 2. Train Process Participants in New Process 3. Fine-tune New Process and Take After Digital Pics 4. Retime and Compare to Goals, Objectives 11/30 Thursday 1. Run New Process and Assess Effectiveness 2. Calculate Improvements in Cycle Time, WIP, Cost Savings, Etc. 3. Complete New Takt Time Cycle Time Bar Chart and Create 30 Day Follow-up List 4. Complete New Standard Operating Procedure 5. Prepare Presentation, Assign Presenters 12/1 Friday UNCLASSIFIED / FOUO 54
  • 55. UNCLASSIFIED / FOUO RIE Team Selection  Team Selection: Typically Area leader, group leader or someone close to process activities, but not a member of management. Identify team members (this can be a bottleneck- keep it moving!)  Team Selection Criteria: Optimum number of team members is 6-8. Three team members must come from the following areas: 2 individuals whom directly work within the project area (i.e. process participants), 1 individual who supervises or leads the project area (i.e. supervisor), the rest of the team can come from the following areas, in order of importance:  Individuals from the direct upstream process (i.e. order entry, purchasing agent)  Individuals from the direct downstream process (i.e. accounts receivable, customer service)  Support personnel (information technology, purchasing, engineering, etc)  Management staff of the project area (i.e. Division Manager, Operations Officer, Engineering Manager, etc.)  Other cross functions (i.e. HR, Headquarters functions, or other divisions) to provide “out-of-the-box” ideas  Insisting that management (Commander, Div Chief, etc.) participate on one of the first RIE teams is critical. This is an effective vehicle for demonstrating to the troops how important the effort / RIE is to fostering continuous improvement and motivating the team members to succeed UNCLASSIFIED / FOUO 55
  • 56. UNCLASSIFIED / FOUO RIE External Resource Support Information Technology:  Schedule information meeting to detail approach and goals for each project to inform & prep them for potential software/programming needs & ideas.  Gives the IT department a head start on preparation for the event Facilities (example – co-location, 6S)  Schedule information meeting to walk the process for each project to inform and prep them for potential moves & ideas.  In addition, facilities resources can assist with additional scoping and costs of the event UNCLASSIFIED / FOUO 56
  • 57. UNCLASSIFIED / FOUO RIE Logistical Support  Logistical Support Checklist:  Training/team room(s), Conference Room(s), Eating Areas - reserve RIE team room and rooms for team reviews/presentations, break/lunch/snack areas  Equipment & supplies: overhead projector, video camera & tapes for set-ups, 2-3 flip charts per team with markers  Team member name tags, special access security cards  Rulers/Tape Measures  Transparencies for presentation / PowerPoint file for LCD projector, copies of presentation  Pens/Pencils, fine-point makers, erasers, multi-colored post-it notes, notepads, clipboards, tape (Masking, Floor / layout), Pre-printed RIE forms  Calculators, computer, printer, copier, laminating machine and supplies  Safety and Cleaning Supplies - eye & hearing protection, clean suits, cleaning supplies  Breaks/Lunches/Snacks/Drinks - coordinate team meals/snacks when applicable and who will be responsible for coordinating these UNCLASSIFIED / FOUO 57
  • 58. UNCLASSIFIED / FOUO RIE Logistical Support (con‟t)  Process Preparation:  May want to process ahead (work ahead by working overtime) to cover for RIE work stoppages or interruptions. For example, a RIE team may want to create case teams requiring co-location - work will probably be interrupted while the furniture is moved  May need to change product mix for RIE product focus. For example, a RIE team may work with order entry to change the schedule to improve rework for a product family UNCLASSIFIED / FOUO 58
  • 59. UNCLASSIFIED / FOUO RIE Kickoff & Training Materials  Team Notification Letters  Include team schedule/agenda, dates, times and meeting room information.  Set expectations concerning full-time status  Set expectations for high level approach and goals of the event  Send out one week prior to event  Training Materials  Tailor training module(s) to specific area focus, if possible. Produce copies of training manuals for team use. Make poster size worksheets for the RIE workshop (fishbone, team ground rules, 20- day follow-up).  Prepare some form of RIE team recognition. (i.e., hats, shirts, certificates printed)Released 07/06/09 UNCLASSIFIED / FOUO 59
  • 60. UNCLASSIFIED / FOUO RIE Kickoff & Training Materials  Kickoff and Review Sessions  Plan for top leader (Commander, etc.) to launch team with motivational, appreciative kick-off  Schedule appropriate personnel for Process Participant Design Review (incl. HR and EH&S)  Schedule the Management team for the Mid-Week Review and Final Team Presentations UNCLASSIFIED / FOUO 60
  • 61. UNCLASSIFIED / FOUO RIE Additional Considerations  Provide emergency contact telephone numbers for each Team Member  Use proper lifting techniques and devices (esp. 5S and co-locate)  Identify hazardous waste materials and/or toxic chemicals in project area  Identify specific project area ergonomic issues  Identify specific project area hazards UNCLASSIFIED / FOUO 61
  • 62. UNCLASSIFIED / FOUO RIE Team Meeting Effectiveness  Post Prominently in the team room and review daily/frequently:  RIE Scope and Goals  Ground rules for team member behavior  Agenda for the session, day and week  Team roles (lead, co-lead, session facilitator, timekeeper, scribe, experts)  Parking Lot  Benefits and ConcernsReleased 07/06/09 UNCLASSIFIED / FOUO 62
  • 63. UNCLASSIFIED / FOUO Appendix RIE Example Results UNCLASSIFIED / FOUO 63
  • 64. UNCLASSIFIED / FOUORapid Improvement Event - Results Event: F-100 Propulsion Shop RIE Team Leads: Mr. Steve Holland (DS2) MSgt DW Glass (325 MXS) Location: Tyndall AFB, Panama City, FL Date: August 21 - 25, 2006 UNCLASSIFIED / FOUO 64
  • 65. UNCLASSIFIED / FOUO RIE Charter UNCLASSIFIED / FOUO 65 65
  • 66. UNCLASSIFIED / FOUOF-100 Propulsion Shop Team  Mr. Steve Holland DS2 Co-Lead  MSgt DW Glass JEIM Flight Chief Co-Lead  Mr. Todd Benz DS2  A1C Chris Brown 325 MXS  Col(S) Bruce Danskine AFSO21 Randolph  Mr. Mike Jones DS2  TSgt Bill MacCarty AFSO21 Tyndall  SSgt Lee McDuffie 325 MXS  Mr. Kevin Morrow Dover AFB, Prop. Shop  Mr. Brian Nugent AFSO21 Randolph  Mr. Gary Poland QAE  Mr. Chad Sowell F-100 Propulsion AFETS  MSgt Tim Walker JEIM Section Chief  Ms. Kristin Witt AFSO21 Tinker  Capt Glenn Wright AFSO21 Tyndall UNCLASSIFIED / FOUO 66 66
  • 67. UNCLASSIFIED / FOUO “Before” Situation Summary UNCLASSIFIED / FOUO 67
  • 68. UNCLASSIFIED / FOUO Before Situation Flow Lead Time Estimate – 10 – 14 Days Through Process With AWP & AWM – 60 Day Average UNCLASSIFIED / FOUO 68 68
  • 69. UNCLASSIFIED / FOUO Before Situation Flow Engine Travel – Black Lines Engine Component Travel – Blue Lines Total Travel Per Engine – 9,700 Feet UNCLASSIFIED / FOUO 69 69
  • 70. UNCLASSIFIED / FOUOBefore Situation – Walk Distance Mechanic Walk (Orange) – 5 Miles Worker Walk (Blue) – 30 Miles Total Walk Per Engine – 35 Miles UNCLASSIFIED / FOUO 70 70
  • 71. UNCLASSIFIED / FOUO Before Situation Summary  Lead Time  Core or LPT - 10 Days  Double Duct - 14 Days  Average with AWM & AWP – 60 Days  25 Engines (Forced Reduction to 15 In Process)  AWM & AWP – 5 Engines  WIP – 10 Engines  Serviceable – 10 Engines  Production Floor Space – 8,720 Sq. Ft. (plus storage)  Part Travel Distance – 9,700 Ft. Per Engine  Walk Distance – 35 Miles per Engine UNCLASSIFIED / FOUO 71 71
  • 72. UNCLASSIFIED / FOUO Flow Pace (TAKT Time)  Average of 4 Scheduled Engines per month  Average of 5 Unscheduled Engines per month  Average of 20 Work Days per month  TAKT Time = 2 Days  2 “Super Crews” each at TAKT Time of 4 Days UNCLASSIFIED / FOUO 72 72
  • 73. UNCLASSIFIED / FOUO Work Structure Changes  2 Super Crews Established  4 Workers  2 Mechanics  Same Total Manning as before  4 Day TAKT Time  Ebb & Flow of Process  Tear Down and Service  Build-up  Crew Chief  Handles Paperwork, CAMS, etc.  Handles Parts Ordering UNCLASSIFIED / FOUO 73 73
  • 74. UNCLASSIFIED / FOUO Layout Changes UNCLASSIFIED / FOUO 74 74
  • 75. UNCLASSIFIED / FOUO Before & After UNCLASSIFIED / FOUO 75 75
  • 76. UNCLASSIFIED / FOUO Before & After UNCLASSIFIED / FOUO 76 76
  • 77. UNCLASSIFIED / FOUO Parts at Point of Use Transforming “Rusty Cabinet” into new POU Parts Storage System UNCLASSIFIED / FOUO 77 77
  • 78. UNCLASSIFIED / FOUO Tools at Point of Use UNCLASSIFIED / FOUO 78 78
  • 79. UNCLASSIFIED / FOUO Equipment at Point of Use Changing Before After UNCLASSIFIED / FOUO 79 79
  • 80. UNCLASSIFIED / FOUO Extra Equipment? UNCLASSIFIED / FOUO 80 80
  • 81. UNCLASSIFIED / FOUO “Infectious” AFSO21 RIE Before Chemical Desk next Just Do It! to Chemicals UNCLASSIFIED / FOUO 81 81
  • 82. UNCLASSIFIED / FOUO Improved Walk Distance  Mechanic (Orange) reduced to 1.06 Miles  Worker (Purple) reduced to 1.33 Miles  Based on reduced distances, fewer flow days, kitting, POU, etc. UNCLASSIFIED / FOUO 82 82
  • 83. UNCLASSIFIED / FOUO Projected Improvements Item Before After Savings Lead Time 10–14 Days 8-9 Days* 20 - 35% Part Travel 9,700 ft. 9,450 ft. 2.5% Walk Distance 35 Miles 2.4 Miles 93% WIP 10 Engines 5 Engines 50% Floor Space 8,720 sq. ft. 7,460 sq. ft. 1,260 sq. ft.** * Estimate based on Improved Flow – Actual Results will be tracked ** Plus additional savings in Storage & Spares Barn UNCLASSIFIED / FOUO 83 83
  • 84. UNCLASSIFIED / FOUO Action Item Tracking UNCLASSIFIED / FOUO 84 84
  • 85. UNCLASSIFIED / FOUO Long Term Challenges  Buy-in and Culture Change needed in shop  Reinforce need for Continued Improvement  Workplace Environment Improvements  Ensure Clarification of On/Off Equipment (in our favor)  Streamlining of Work Package & CAMS  Identification of Future Workload  Advertising Excess Capacity once proven  Future Discussions on Contract Issues causing separation of DS2 & Military UNCLASSIFIED / FOUO 85 85