The Missing Link

Transcription

1 The Missing Link

2 TWI Integration into Production s Change Management Campaign Executive commitment Communication campaign Lean and Six Sigma Training Value Stream and Process Mapping Job Relations Deployment Create FLOW (PULL if needed) Cellular Manufacturing Job Instruction Deployment Mixed Model, one-piece flow, Kanban Standard Work Variation control Continual Improvement Root cause problem solving at the source Visual workplace Suggestion system Job Methods deployment

3 The TWI Pathway to Continuous Improvement Recognize need to implement continuous improvement Commitment to culture shift Production Introduction Deployment Measurable Successes Backsliding Early Stage Existing Mature

4 Integration of TWI ü Change Management Standardization Continuous Improvement 4

5 The TWI Pathway to Continuous Improvement Recognize need to implement continuous improvement Commitment to culture shift Method Selection & Introduction Method Deployment Measurable Successes Backsliding Early Stage

6 Change Management Roadblocks Denial, current HR systems work Fear of change Flavor of the week Lack of management support/buy in We re different Too busy, no time to change Already have supervisory training 6

7 Countermeasures Roadblocks Denial, current HR systems work Fear of change Flavor of the week Lack of management support/buy in We re different Too busy, no time to change Already have supervisory training Job Relations Get the facts-review the Record Feelings and Opinions Tell people in advance of changes that will affect them Make the best use of Each Person s abilities Check Results-Follow up Treat people as individuals Give credit when due Did you accomplish your objective? 7

8 Implementation Models Job Relations: Consensus on one best way Discovery of hidden talent Conflict management Self directed workforce Skilled workforce shortage 8

9 The TWI Pathway to Continuous Improvement Recognize need to implement continuous improvement Commitment to culture shift Production Introduction Deployment Measurable Successes Backsliding Early Stage Job Relations

10 Integration of TWI Change Management ü Standardization Continuous Improvement 10

11 The Lean/TWI Pathway to Continuous Improvement Recognize need to implement continuous improvement Commitment to culture shift Production Introduction Deployment Measurable Successes Backsliding Existing

12 Standardization Roadblocks We have documented procedures, no one follows. Operators are individuals, not robots. What we do is art, not science. Waste of time to train-turnover. No time to train. 12

13 Countermeasures Roadblocks We have documented procedures, no one follows Operators are individuals, not robots What we do is art, not science Waste of time to train-turnover No time to train Job Instructions If the worker hasn t learned the instructor hasn t taught. Job Relations-People must be treated as individuals. Breakdown the job. Make sure the person understands, continue until you know they know Instruct clearly, completely and patiently. 13

14 Job Instructions: Implementation Models 1. Train initial group of (10) employees in 10 hr. TTT for select group to continue spread of method. 300 employees. 2. Trained 30 employees (20%), (10) team leads included (100%) with external resource coaching, no TTT. 150 employees. 3. Trained 10 initially, 2 TTT who deployed 4 individuals as company trainers in two separate departments. 450 employees. 4. Self taught, held 2 day workshop for corporate black belts on finer points of Job Breakdowns with TWI-Institute and external resource coaching, no TTT. 110 employees. 14

15 The TWI Pathway to Continuous Improvement Recognize need to implement continuous improvement Commitment to culture shift Production Introduction Deployment Measurable Successes Backsliding Early Stage Existing Job Relations Job Instructions

16 Integration of TWI Change Management Standardization ü Continuous Improvement 16

17 The TWI Pathway to Continuous Improvement Recognize need to implement continuous improvement Commitment to culture shift Production Introduction Deployment Measurable Successes Backsliding Early Stage Job Relations

18 Continuous Improvement Roadblocks Fear of change No one listens It doesn t stick Too busy, no time to change Costs money Someone else s job (process/quality engineers) 18

19 Countermeasures Roadblocks Fear of change No one listens It doesn t stick Too busy, no time to change Costs money Someone else s job (process/ quality engineers) Job Methods Job Relations Tell people in advance about changes that will affect them Sell the new method Job Instructions If the worker hasn't learned the instructor hasn t taught Eliminate unnecessary details The best use of the Manpower, Machines and Materials now available. Who is best qualified to do it? 19

20 The TWI Pathway to Continuous Improvement Recognize need to implement continuous improvement Commitment to culture shift Production Introduction Deployment Measurable Successes Backsliding Early Stage Existing Mature Job Relations Job Instructions Job Methods

21 Implementation Models Job Methods: 1. Form submitted to review team, implemented by floor and submitter is given recognition at monthly meetings 2. Team Lead creates submission form with operators for review to staff. Upon acceptance floor is given resources to implement changes. 3. Individuals submit change suggestion on form and develop new method after acceptance by review team. 21

22 The TWI Pathway to Continuous Improvement Recognize need to implement continuous improvement Commitment to culture shift Production Introduction Deployment Measurable Successes Backsliding Early Stage Existing Mature Job Relations Union Job Relations Job Safety Job Instructions Job Methods

23 TWI Cultural Integration Executive Pledge Change Management Program Designated TWI Champions Practice TWI Where Value is Created and Multiply Management Support 23

24 TWI Integration Requires working through people, Job Relations Stabilize your work method Job Instruction and Standardized Work Evaluate and improve your work method Job Methods with Lean techniques Stabilize your improved work method Job Instruction and Standardized Work

25 What s Next Union Job Relations: Job Relations targeted toward Union Stewards. Job Safety: Modeled after Job Relations and is designed to prevent accidents from happening and not resolve the aftermath. 25

26 The TWI Workbook: Essential Skills for Supervisors A Shingo Research and Professional Publication Prize Recipient for 2007 Patrick Graupp and Robert J. Wrona 26