Dynamic Value Stream Transformation

Transcription

1 Welcome Fellow CI Practitioners Dynamic Value Stream Transformation Rod Smith Director of Operation Excellence The Duha Group

2 Who We Are

3 The Duha Group of Companies Members Canada USA Australia Partners Mexico China 2005 UK Joint Ventures Singapore Germany = 800+ Lean Champions

4 Markets Served Customers in 100+ Countries =

5 What We Do

6 Leaders in Colour Sampling Products used by... Retail Paint Industry Paint Manufacturers Automotive Paint Industry Other various color or texture specific industries

7 Wal-Mart

8 Our Primary Focus Dynamic Value Stream Transformation through Learning Strategies & Employee Engagement

9 What does Value Stream really mean? For us it s having a strategic Roadmap that navigates our Journey in a Safe, Balanced and Respectful manner for all stakeholders

10 And trust me they call it a Never Ending Journey for a Reason! And we certainly don t always get it right the first time!!

11 = Dynamic Value Stream Transformation Awareness Period Culture Change Period Engagement Period Succession Period Sustainability Period = Behavior Focus

12 Where to Start Driving your Journey starts with a Vision Developing a Vision required the ability to Change Change requires the ability to look at things differently

13 A good place to start is setting your Value Stream Priorities when it comes to Continuous Improvement

14 Where does Continuous Improvement really sit in your Organizations Value Stream Strategy? OR 50% Admin., Sales, Market. = Input 50% Actions, Ops., Prod. = Output CI Alignment when required OR 33% C.I. = Balanced Alignment 33% Admin., Sales, Market, Admin. = Input 33% Actions, Ops, Prod. = Output It s a Shift you may want to consider!

15 How We Balance our Value Stream

16 Dynamic Value Stream Transformation Customer / Supplier Huddles Organizational Transparency Value Stream Alignment Facility Strength Turbo Kaizen Department Alignment Visual Communication Customer / Supplier E-Kanban Customer / Supplier Balancing Individual Growth Passport to World Excellence Customer / Supplier Value Stream

17 Value Stream #1 People First Individual Growth Passport to World Excellence

18 Value Stream Transformation Starts Here!! People - Growth System

19 The Duha Passport is their Roadmap

20 Linking our Global Facilities by Standardizing Learning Strategies

21 The Passport System Understanding - Implementing - Training Others - Coaching - Black Belt 67% Allows team members to grow at their own pace while making gradual improvements to our organization Peer training though Learn and Do (Kata)

22 Recognizing People and Improvements One Chip at a Time Think Airmiles but not for spending money but rather Energy and Brainpower

23 Allows Everyone to Share in Success Even if we have Different Opinions

24 Have we seen results? 95.1% Retention average over the last 10 years (industry average 86%) $120,000+ earned by the employees through CHIPS for their Continuous Improvement efforts

25 Value Stream #2 Home Values Department Alignment Visual Communication Individual Growth Passport to World Excellence

26 Department Value Stream Cycle

27 Employee Communication Systems Promotes individual growth through communication sharing and leading results in team building and confidence.

28 Building Future Champions starts with Communication Skills!

29 Department Engagement Systems Activity Centers promoting ownership and accountability in a positive manner

30 Our Shared Vision at Duha Color Services One improvement every day in every department through Team-Work and Communication

31 Have we seen Value? 24, Feet of Stickie's!

32 Additional Findings! Positive Departmental / Corporate Benchmarking & sharing of Best Practices

33 A Must is a No Blame Environment

34 Value Stream #3 Community Respect Facility Strength Kaizen Strategies Department Alignment Visual Communication Individual Growth Passport to World Excellence

35 Value Stream Communication Alignment Department #2 Department #1 Department #3 Department #4

36 The 12 Step Standardized Duha SIG & Turbo Kaizen System Champion, Resource and Facilitator Tool System Standardize your Kaizen Strategies with System Kits to ensure You Finish what you Start

37 The Duha 12 Step Visual Tools of the Trade 12 Step Turbo Kaizen System Value Stream Mapping System Spaghetti Diagram Analysis System SWOT Analysis System

38 The 12 Step Turbo Kaizen System 1. Kaizen Identification, Assessment, Team Selection and Training 2. Power Charter and Target Setting 3. Critical Path Implementation Plan HANSEI CHECK POINT! 4. Opportunity Identification 5. Prioritization and Implementation 6. Standardize by developing Visual SOP s 7. Sustainability -Visual Assist Photograph (VAP) installment (other) 8. Critical Path & Targets Review 9. Distribute all incomplete ideas onto Huddle Centers 10. Safety / Environmental Audit Check 11. Kaizen System Continuous Improvement Team Hansei 12. Celebration: Present Out and Newsletter Article

39 It s ALL about Team Work when Planning for Change

40 It Starts with Opportunity Identification

41 Performance Alignment Systems Point Us in the Right Direction Department Align Core Key Performance Indicator Centers link to the Business Goals

42 Everyone Wins when we Share and Promote Results to the entire Value Stream Capture, Recognize and Reward Great Ideas and build upon them

43 Kaizen Alignment can be Amazing if Done well!

44 Have we seen results? Reduced cycle time on system work from 16 weeks to 3 weeks (Customer to Delivery) Inventory reductions of 75% through Vendor Managed Kanban and E-Kanban implementation

45 Value Stream #4 Business Transformation Organizational Transparency Value Stream Alignment Facility Strength Kaizen Strategies Department Alignment Visual Communication Individual Growth Passport to World Excellence

46 Organizational Value Stream Alignment People Department #2 Department #1 Department #3 Facility Organization

47 Respect our Employee and Partners Core Value Alignment

48 Cultural Behavioral Awareness Systems Staff identify what the 6-S, 9 Wastes and Organizational Core Values means to them Realizing why we do this

49 Linked Visual Management Systems Easy to use and understand - allowing 100% participation

50 Daily - 30, 90 Day, 1, 3 and 10 Year KPI Alignment Strategy Systems Links to the Individual, Department, Facilities and the Organizational core targets and goals

51 Organizational Alignment in the Value Stream makes Help a Habit

52 Have we seen results? Only Global Manufacturer of Color Aides left in the Industry Reduced our Canadian footprint from 450,000 square feet to 125,000 Square feet while increasing through by 3X s While still increasing staff levels by 34%

53 But-we are only as strong as our Weakest Link! Customer Duha Supplier = We need to ALL be Partners in this journey

54 Dynamic Value Stream Transformation Customer / Supplier Huddles Organizational Transparency Value Stream Alignment Facility Strength Turbo Kaizen Department Alignment Visual Communication Customer / Supplier E-Kanban Customer / Supplier Balancing Individual Growth Passport to World Excellence Customer / Supplier Value Stream

55 Customer/ Supplier Communication

56 Customer/ Supplier Vendor Managed Kanban

57 Customer/ Supplier Value Stream Alignment

58 Customer/ Supplier Balancing

59 Opportunities are found throughout the Entire Value Stream Sometimes you just have to Laugh

60 Dynamic Value Stream Transformation is in our DNA

61 Thanks for letting us share a piece of our story A Never Ending Journey but One Worth the Effort

62 Thank You! Please complete the session survey at: Session:ThP/52 Presentation Title 28pt Helvetica bold (black) Rod Smith The Duha Group