What does it take to adapt in today's world? Implement industrial Darwinism. It is not the strongest that survives, but the most adaptable. This presentation will show you how to deploy Adaptive Production Systems to reach continuous improvement. This is an evolutionary step to simplify the complex methods of Lean and Six Sigma. This is achieved by developing a different behaviour throughout the organization: coaching people to simplify their life at work results in ever improving performance. The paradygm here is that simplifying people's life at work will result in performance improvements, as opposed to the traditional push approach for improvement to expect better results.

1. Adaptive Production Systems®
Franck Vermet 2016

2. Adapt = Improve = change Behavior

3. Production Systems Basics
INPUTS OUTPUTSPROCESS
Supplier Customer
a

4. Standard Outputs
INPUTS OUTPUTSPROCESS
Safety
Morale
Quality
Time
Cost
a

5. Standard Process Steps
INPUTS OUTPUTSPROCESS
Safety
Morale
Quality
Time
CostStore
Setup
Add
value
Check
Transport
a

6. Standard Inputs
INPUTS OUTPUTSPROCESS
People
Materials
Methods
Machinery
Environment
Safety
Morale
Quality
Time
CostStore
Setup
Add
value
Check
Transport
a

7. PROCESSINPUTS OUTPUTSCheck
Structure the system
Process mapping
Critical Skills identification, capture and transfer
Instruction
a

8. PROCESSINPUTS OUTPUTSCheck
Discover problems
Quantitative: Data analysis
Qualitative: Shop floor
a

9. PROCESSINPUTS OUTPUTSCheck
Implement a reactive feedback loop
Root Cause Analysis / Containment
Problem
solving
a

10. PROCESSINPUTS OUTPUTSCheck
Stabilize the System
Instruction
Problem
solving
a

11. PROCESSINPUTS OUTPUTSCheck
Stabilize the System: Lean methodology
Instruction
Problem
solving
The 7 wastes = 3 for Quality + 4 for Time = $
a

12. a
Defects
The 7 wastes

13. PROCESSINPUTS OUTPUTSCheck
Stabilize the System: Lean methodology
Instruction
Problem
solving
The 7 wastes = 3 for Quality + 4 for Time = $
The Lean Toolbox = Surface and fix systemic problems
a

14. a
Standard Solutions

15. PROCESSINPUTS OUTPUTSCheck
Stabilize the System: Lean methodology (PDCA)
Instruction
Problem
solving
The 7 wastes = 3 for Quality + 4 for Time = $
The Lean Toolbox = Surface and fix systemic problems
a

16. PROCESSINPUTS OUTPUTSCheck
Stabilize the System: Six Sigma methodology (DMAIC)
Instruction
Problem
solving
Measure
Improve
Analyze
Control
Define
the problem
Sigma
level
Defects
(ppm)
Defects
(%)
1 691462 69%
2 308538 31%
3 66807 6.7%
4 6210 0.6%
5 233 0.02%
6 3 0.0003%
a

17. PROCESSINPUTS OUTPUTSCheck
Instruction
Problem
solving
Measure
Improve
Analyze
Control
Stabilize the System: Six Sigma methodology (DMAIC)
Define
the problem
a

18. Adaptive Production Systems
PROCESSINPUTS OUTPUTSCheck
Process
improvement
Proactive Loop:
Instruction
Problem
solving
a

19. Adaptive Production Systems =
6 basic training modules + coaching
PROCESSINPUTS OUTPUTSCheck
Instruction
Problem
solving
Process
improvement
Process / heat mapping
Skills identification, capture and transfer
1
2
6
5
Quantitative: Data analysis
Qualitative: Shop floor walk
3
4
a

20. Deploy Adaptive Production Systems
The What = build people who build the System - Long term
By the Why = solving short term Cost, Quality or Time problems
How?
m

21. The What = build people who build the System - Long term
By the Why = solving short term Cost, Quality or Time problems
How?
Deploy Adaptive Production Systems