A new way to achieve process excellence C P CHANDRASEKARAN NOV 2011 SMILE A new way to achieve process excellence C P CHANDRASEKARAN NOV 2011

Current improvement paths Kaizen 5S/TPM TBEM ISO 9001 7 QC tools DWM (Japanese way) suited for small shops. Suited only for manufacturing. One year cycle Emphasis on conformance Not appealing to executives –a view that it is too simplistic Not caught on in India except with Deming prize applicants. Six sigma (DMAIC) is popular Lot of interest but there are issues

Difficulties in six sigma-DMAIC Team spends too long a time in analysis and loses steam when it comes to improvement. Team leaders do not gain the required expertise in statistical tools in spite of the training. Teams unable to hold back some initial ideas which they want to try but the method does not allow them. Faculty seem to be more attached to methodology and not interested in customising it for the teams.

DMAIC distribution of time –current experience Define Measurement Analysis Improve control 20% 40% 10% Poor show Improvement gets 10% of the cycle !! (real value addition)

Cycle time 6 months is too long In today’s organisational priorities, a six month cycle is just too long because- People get transferred Their roles get changed Members get other assignments. Management loses interest.

Need of the day Spirit of PDCA and Cause and effect diagram should be kept alive. Complex tools to evaluate results should be handled by experts. Improvement and innovation should be brought to the fore. Leading the change should be given due importance. In short, we need a LIVE and VIBRANT methodology not a PROSAIC one. After all, We need to SMILE !!!!!! at the end of the day.

SMILE is a shorter and pruned DMAIC for busy executives S= Set Goal. M= map the process. I=Identify key factors for improvement. L= Lead the change. E=Evaluate the effect of change.

S= Set the goal S= Set the goal. You need to set a goal which is important to you , your area and the organisation. Tools used: Nil Time taken = 1 week

M=Map the process Map the process which you think you need to focus for removing the bottleneck and the pain. Tools used : Process flow chart. Time taken= 1 week

I=Identify the key factors Which factors do you think are very much responsible for the situation in which we are in? Cause and effect diagram/pareto/correlation Time taken= 2 weeks

L=Lead the change Take a decision to change the factors Tools used: Brainstorming, solution mapping, six thinking hats, affinity diagram, Force field analysis Time taken= 6 weeks

E=Evaluate Use the techniques to evaluate the effect of the change on the output. If the evaluations shows there is improvement, go ahead and replicate in other places. If not, repeat the identification and change management Tools used: Pareto/hypothesis testing etc Time taken= 2 weeks

Distribution of time in SMILE Set the goal= 1 week Map the process= 1 week Identify key factors= 2 weeks Lead the change= 6 weeks Evaluate= 2 weeks 8 % 17 % 50% Improvement takes 50% of the cycle

SMILE addresses the needs The need is to Have a shorter cycle time More emphasis on realising improvements and less on analysis. Less dependence on statistical part of the tools or taking it to a separate group. Grooming the leaders in change management. 12 weeks 50 % for leading the change BIG facilitators to apply statistical tools and evaluate the projects. Change management and sustaining is given more importance SMILE You are there!

The team focuses on improvement BI auditors focus on evaluation The team should focus on identifying the factors which are needed to improve and implement suggestions for improving them. Evaluation of the extent of improvement is taken out of the team’s purview and put in the hands of the trained group of facilitators. We will have a group of experts trained in statistical tools and software who will validate the improvements. They will also perform the required audits to sustain the improvements achieved.

Resources mobilisation Focus on improvement Focus on evaluation of effect of the improvements Focus on training and helping the facilitators with a (GB methodology) certification Team leader + members Top management led facilitators External consultant Speed in driving the change Consistency in evaluation

Thank you Confidentiality and usage of the content: SMILE * is currently under development by C P Chandrasekaran and its use either as a methodology or otherwise by anyone is not allowed without the express permission of the above named consultant. Contact for permission: cpchandrasekaran@gmail.com C P Chandrasekaran, C2 505 shubhashree Residential, Jai ganesh Vision Phase 1, Pune. Maharashtra. India.