The document outlines a webinar and podcast series focused on continuous improvement methodologies for process manufacturers, led by experts Brandon Wright and Eric Hansen. It covers key strategies for improving yield and productivity, the implementation of various improvement techniques like the Theory of Constraints and Statistical Process Control, and emphasizes the importance of having a structured CI process. Additional resources and case studies are provided to support the adoption of continuous improvement practices.

1. Beyond Compliance
Webinar & Podcast Series for Process Manufacturers
Three Key Methods
to Unlock Continuous Improvement
Across Your Plant
Brandon Wright & Eric Hansen

2. The Sponsor
✔Improve Yield
✔Maximize Productivity
✔Ensure Compliance
Plant Management Platform
BEYOND COMPLIANCE

3. Casual but Professional Format
✔Ask questions! (Q&A at end)
✔Only panelists are displayed
✔Recording link will be shared
✔Audio issues: use call-in number
Before We Get Started
BEYOND COMPLIANCE
Helpful tips

4. About the Presenters
BEYOND COMPLIANCE
Brandon Wright
Customer Success
Coach
Brandon has spent the
majority of his career in
manufacturing roles, from
food manufacturing to
biotechnology, textiles, and
more. He’s worked on the
floor and in management at
Pepperidge Farms, Chobani,
Dannon, Kellogg’s, and even
owned and operated a flour
mill.
Eric Hansen
VP Customer
Solutions
Eric has been designing,
developing, delivering, and
improving business
optimization solutions in the
health care, supply chain
execution, and process
manufacturing and
distribution markets for over
20 years.

5. BEYOND COMPLIANCE
Agenda
● Strategies for approaching CI implementation at your
organization
● Improvement techniques and how to address inefficiencies as
part of the Continuous Improvement (CI) cycle
○ Constraint Analysis
○ Genchi Genbutsu & Kaizen
○ Statistical Process Control
● Stories from the shop floor (and ceiling)

6. BEYOND COMPLIANCE
There’s a lot in the CI toolbox
PDCA
Gemba
Walks
5 WHYS
Kata
Coaching
Muri,
Mura,
Muda
Continuous
Improvement Software
LEAN
Six
Sigma
TQM
ISO 9000
Theory of
Constraints
AGILE
Lean
Start
up
Just in
Time
Jidoka
Continuous Flow
Takt Time
Pull System
Heijunka
KAIZE
N
Growth Hacking
Lean 6
Sigma
8 Wastes
DMAIC
Daily
Huddles
Standard Work
Catchball
Hoshin
Kanri
Kanban Boards
Value Stream
Maps
Kanban
boards
Value
Stream
Map
8 Wastes

7. BEYOND COMPLIANCE
Does your CI Process follow a process?
Three key questions:
1. What is your process?
a. DMAIC, PDCA, Ad Hoc, etc
2. How is your process initiated? How is it focused?
a. Reactive, Proactive, Scheduled
3. How is your process reviewed?
a. Validation of outcomes, blindspots, periodic review
The best indicator of success in any venture is to have a
process and to manage that process.
-Brandon Wright

8. BEYOND COMPLIANCE
Capability Maturity Model (CMM)
Capability Maturity Model
Originally developed in the late 1980s
and early 1990s as a means for the US
Department of Defense (DoD) to
evaluate its vendors’ ability to
effectively deliver on software
development projects.
As with any model, there are flaws,
but we’ll use it for a quick poll…

9. Using CMM, what best describes your
facility?

10. BEYOND COMPLIANCE
This is the way… or one way
Step 1
Document the current state,
and define ideal future state
Step 5
Update metrics, monitor
performance, report results
Step 2
Root cause analysis, solution
testing & selection
Step 4
Monitor, iterate,
finalize, formalize
Step 3
Implement solution
Process
Improvement
Model

11. BEYOND COMPLIANCE
Method 1: Applying the Theory of Constraints
Objective: Increase Throughput
● Theory of Constraints = Focus
○ Map the process flow you want to improve
○ Define the maximum output for each step in the
process
○ ID the constraint and impact if it were improved
● Now you know what to improve, and what the result should
be in terms of Throughput

12. BEYOND COMPLIANCE
Story Time: Theory of Constraints

13. BEYOND COMPLIANCE
Method 2: Genchi Genbutsu
Objective: Proper Problem Characterization
● Lean Principles - reduce or eliminate waste
○ Genchi Genbutsu - Go and See
○ Interrogate and study the data and compare to what
you observed
○ Kaizen events address and improve what you observed
● Evaluate improvements against the goal and expected
outcomes
○ Watch for unintended consequences

14. BEYOND COMPLIANCE
Story Time: The Rafter Perspective

15. How many CI projects has your facility
completed in the last year?

16. BEYOND COMPLIANCE
Method 3: SPC
Objective: Improved Predictable Performance
● An ounce of planning is worth a pound of recovery
○ Process Capability and Target Setting
● Statistical Process Control
○ Data vs. Insight
○ Automated collection & analysis
● Understanding what causes observed results

17. BEYOND COMPLIANCE
Story Time: SPC in Action
● Top 5 poultry processor
○ Usability & digitization
challenge results in new data
visibility
○ Presentation of data draws
response
● SPC Validation Process

18. BEYOND COMPLIANCE
Getting it to stick
Educate and
involve
employees
from the
beginning
Be present
beyond the
project,
check in on
the changes
Update the
metrics…
and inspect
what you
expect (check the metrics!)

19. Q&A
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20. More Resources at www.safetychain.com
White Papers & Surveys
Webinars & Videos
Product & Partner Info
Solution Consultation
3/17/22: Leveraging OEE to Minimize Downtime and
Maximize Performance
3/25/22: FSMA Fridays: RCAs and CAPAs
MARCH: Poultry Federation Conference, Pack Expo East, Modex,
Plastics Tech
safetychain.com/resources/webinars-events/
BEYOND COMPLIANCE