Copyright © Six Sigma Academy International, LLC All Rights Reserved Lean Workshop Progress Jim Walker, Toby Drummond, Robert Vaughn, Rodney Reed and Jim Buike

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 1 Lean team Objectives Develop a process for upgrading our MC to a sufficient lean expertise -Measure the baseline of SSA lean knowledge -Standardize Kaizen material -Recommend Reading material -Promote attendance at Kaizens and other lean training

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 2 Lean team status Develop a process for upgrading our MC to a sufficient lean expertise -Measure the baseline of SSA lean knowledge-Complete -Standardize Kaizen material (see next slide) -Recommend Reading material - Complete -Promote attendance at Kaizens and other lean training-Ready for events

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 3 Developed General Kaizen Training Includes Management introduction Objectives for week Kaizen overview Kaizen expectations Kaizen roles Ten kaizen principles Lean Overview Lean tool roadmap Standard Kaizen Training for Every Kaizen Event Complete

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 4 Developing “Quick” Training module to Support General training Kaizen Introduction-Complete Kaizen Follow up and Standard reporting template- Complete Kaizen strategy-Complete Set up reduction- Complete Material Replenishment- 80% Complete TPM- Complete 5s- Complete Takt flow pull- Complete Mistake proofing - 50% Complete VSM-Complete Process assessment – 80%Complete Training Modules should not take longer than 45 minutes

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 5 Calendar of Kaizens and Training Uses pop up selections Calendar is located on public drive and will allow visibility to training events. Need more dates before we start using it

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 6 Need to push the lean program faster Need to get a list of Kaizens or training at Clients that we can add some SSA resources Consider doing a in-house training classes for MC on lean material Need a formal way to track the progress of our MC’s Aggressively get more MC into lean activities Anthony International and Utilimaster could provide a good vehicle for training

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 7 Appendix

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 8 Baseline Knowledge Survey all employees of Company Scoring Criteria -1 No Knowledge -2 Baseline – Theoretical Knowledge -3 Progressing-Limited practical Application and Experience -4 Proficient-Extensive Practical Application and Experience -5 Master- Recognized Thought Leader 46 Responses to Questionnaire with an average score of 2.96

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 9

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 10 Need to move 1,2,3’s to 4’s and 5’s

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 11 Employees with Score of 4 or 5 Dowden, Richard W Gould, Lawrence J Vaughn, Robert F Drummond, William O Walker, James E Palanna, Rajkumar Lawrence, Charles Rexus, Teressa L Eskandari, Gholam R Buike, James W Shultz, Martin B Aguilar III, Charles A.

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 12 Required Reading Bruce A. Henderson and Jorge L. Larco, “Lean Transformation” (Amazon $17.75) Mike Rother and John Shook, “Learning to See” (Productivity Press $50) - Manufacturing oriented or Don Tapping and Tom Shuker, “Value Stream Management for the Lean Office” (Productivity Press $50) - Transactional oriented 50 Copies = $3388 or if all books $5,888

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 13 Top Lean Book References James Womack and Daniel T. Jones, “Lean Thinking” (Borders) Masaaki Imai “Gemba Kaizen” (Borders) William Lareau, “Office Kaizen” (Productivity Press) Translated by: Andrew P. Dillon, “Shingeo Shingo: The Shingo Production Management System. Improving Process Functions” (Productivity Press) Yashhiro Monden, “Toyota Production System” (good reference textbook) ISBN Iwao kabayashi, “20 keys to Workplace Organization” (good reference on assessment) ISBN *Mike Rother and Rick Harris, 2001 “Creating Continuous Flow”, Productivity Press *Art Smalley, 2004, “Creating Level Pull”, Productivity Press *Rick Harris, Chris Harris, and Earl Wilson, 2003, “ Making Materials Flow”, Productivity Press –* Three book series

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 14 Specific Lean Tool References General Tools and References Japan Management Assoc, 1986, “Kanban and Just-In-Time at Toyota, Productivity Press Shingo S, 1989, “Study of Toyota Production System”, Productivity Press James B. Swartz, 1994, “ The Hunters and the Hunted”, Productivity Press Dave Nelson, Rick Mayo, and Patricia Moody, 1998, “Powered by Honda” (good reference on supplier development) Anthony C. Laria, Patricia Moody, and Robert Hall, 1999,”The Kaizen Blitz”, Borders Shigeo Shingo, “Zero Quality Control: Source Inspection and the Poka-Yoke System “ Jeffrey K. Liker (Foreword), Kevin J. Duggan, “Creating Mixed Model Value Streams: Practical Lean techniques for Building to Demand”, Borders

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 15 Specific Lean Tool References 5S and Visual Management References Grief M, 1991, “Visual Factory”, Productivity Press Hirano H, 1996, “5S for Operations: 5 Pillars of the Visual Workplace”, Productivity Press Peterson J & Smith R, 1998, “5S Pocket Guide”, Productivity Press Press Galsworth G, 1997, “Visual Systems” Amazon.com Shimbun K, 1995, “Visual Control Systems”

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 16 Map things as they are Measure Flow value added activities and train Measure again Celebrate the accomplishments Eliminate what does not add value Start here Developed Standard Kaizen Process material Includes Details On The Four Phases Of Kaizens

Copyright © Six Sigma Academy International, LLC All Rights Reserved Title Slide Team Name Company Name Site Location Date Developed Standard Kaizen Templates

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 18 Team Names Use digital pictures Note names and titles Team Roles

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 19 Team Charter Insert Charter or Detailed Problem Statement List Project objectives

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 20 Summary of Activities Breakdown methodology used during the event – What was the thought process your team used to solve the problem

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 21 Discovery tool usage examples Insert tools used in the Discovery phase Example: -Current Value Stream Map -Before pictures -Waste walk -Spaghetti chart -Metrics/Charts -Fishbone

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 22 Improvement/Actions Examples Insert tools used in the Improve phase Example: -Future State Value Stream Map -After 5S audit -After Pictures -Pilot results -Standard work forms/Procedures

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 23 Improvement/Actions Examples More Tool Examples

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 24 Accomplishments List non metric accomplishments -Training -Changed layout -Created tool boards -Poke Yoke devices

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 25 Before and After Metrics Compare Baseline and Current Performance Metrics Example: -Control Chart -Floor Space -Travel distance -VA vs. NVA -Productivity/ Load Chart

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 26 Follow Up Actions Insert RAIL and/or Kaizen Newspaper -Insure Names, Dates, and Action are included

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 27 Questions and Closing Comments Thank the team Thank management Recognize support functions

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 28 Action Item List ActivityResponsibilityDate DueStatusComments 1Standard Kaizen Strategy (4 Phases)Team8/15/2005FormatingRobert to send to Jennifer Altuna for formating 2Kaizen Introduction and Lean overviewTeam8/15/2005FormatingRobert to send to Jennifer Altuna for formating 3Report-out TempleteToby Drummond8/31/2005 Need examples and formating 4 Develop Master Consultant LEAN Skills MatrixRobert Vaughn8/4/2005CompletedSent out to all Employees 5Analyze the MC LEAN Skills MatrixRobert Vaughn8/31/2005Receiving data 6Reference reading listJim Walker9/15/2005Procurement 7Kaizen CalendarRodney Reed9/15/2005Reformating and Posting 8TPMToby Drummond10/1/2005Creating Plus support files, No More Than 30 Slide! All extras should be in appendix. 95-SRobert Vaughn10/1/2005Creating Plus support files, No More Than 30 Slide! All extras should be in appendix. 10Set-up ReductionRodney Reed10/1/2005Creating Plus support files, No More Than 30 Slide! All extras should be in appendix. 11VSMJim Walker10/1/2005Creating Plus support files, No More Than 30 Slide! All extras should be in appendix. 12TAKT-Flow-Pull / Standard WorkToby Drummond10/1/2005Creating Plus support files, No More Than 30 Slide! All extras should be in appendix. 13Material ReplenishmentRobert Vaughn10/1/2005Creating Plus support files, No More Than 30 Slide! All extras should be in appendix. 14Mistake ProofingJim Buike10/1/2005Creating Plus support files, No More Than 30 Slide! All extras should be in appendix. 15R.A.I.L. / Kaizen NewspaperRodney Reed10/1/2005Creating Plus support files, No More Than 30 Slide! All extras should be in appendix. 16Process AssessmentRobert Vaughn10/1/2005Creating Plus support files, No More Than 30 Slide! All extras should be in appendix. 17Bi-weekly Phone ConferenceTeamWeeklyOngoing 18 Action Item List is Updated Every Two Weeks

Copyright © Six Sigma Academy International, LLC All Rights Reserved Pg 29 The following are trademarks and service marks of Six Sigma Academy International, LLC: Breakthrough Lean ®, Breakthrough Strategy ®, Breakthrough Value Services ®, Breakthrough Change Strategy SM, Breakthrough Design SM, Breakthrough Diagnosis SM, Breakthrough Execution SM, Breakthrough Sigma Lean SM, Breakthrough Six Sigma SM, Breakthrough Software Design SM, FASTART SM, Six Sigma Gold Belt TM, SOLVING YOUR BUSINESS PROBLEMS FOR THE LAST TIME SM. Six Sigma is a federally registered trademark of Motorola, Inc. MINITAB is a federally registered trademark of Minitab, Inc. SigmaFlow is a federally registered trademark of Compass Partners, Inc. VarTran is a federally registered trademark of Taylor Enterprises. Six Sigma Academy International, LLC 8876 East Pinnacle Peak Road, Suite 100 Scottsdale, Arizona Tel. (480) Fax (480)