1. The Global Lean Transformation Program
Transformation by the numbers
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

2. This presentation is based on publicly available information;
DISCLAIMER
This presentation is based on publicly available information;
These slides are intended for educational purposes only and for the personal use of the audience. These slides are not intended for wider distribution outside the intended purpose without presenter approval;
The content of this slide deck is accurate to the best of the presenter’s knowledge at the time of production. 
The views and opinions expressed in this presentation are those of the author and do not necessarily reflect the official policy or position of Roche or any of its officers.
The views and opinions expressed in this presentation are those of the presenter. They do not reflect any strategic or business intent of their employer and they are not considered in any way a public communication of the presenter’s employer. The presenter’s employer does not endorse or support the views and opinions expressed within this presentation.
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

3. Speaker background
Professional Manager with over 20 years of experience as a change agent within manufacturing companies Key leader of Lean Six Sigma business transformation Expert knowledge in the following management tools: Strategic Planning/Policy Deployment, Lean Six Sigma Transformation, Dashboard Metrics, Kaizen, Project Management, Quality System Regulations, CAPA System, DMAIC, and Root Cause Analysis. Facilitated, coached or led over 250 operational excellence events during career.
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

4. agenda Global Lean Transformation Program Strategic Deployment
Value Stream Management
Building People Capabilities
Governance of Lean Program
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

5. Lean Transformational Model
Draft of future state
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

6. Global Lean Transformation- Checklist for Success
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

7. Global Lean Transformation- How to start
Change Management
Selective Tools
SME Development
Training
Organize for OPEX
Provide Resources
Kaizen
Product / Value
Immersion Program
Theory Training
Engagement
Leadership T0
Time
T +12
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

8. The Model to Lean Transformation
Enterprise Strategy
The Model to Lean Transformation
Annually
Annually- Semi-Annually
Strategic Deployment
Monthly, weekly, Daily
ACT
Strategy Deployment L1
Action Items/Countermeasures
Lean Certification- SME
Kepner-Tregoe Problem Solving
Standardization across plant
Managing Culture
Communicate Business Case- Reason for change
Education/Training C H E K
Fundamentals
Dashboard Metrics
Event Pace
Lean ROI
Cross Training Matrix
Event Participation
Cultural Development
Employee Morale/Leadership Development
Spheres
SD Level 2
Toric SD Level 2 P L A N
Semi-annually
Performance Reviews KPI Board Review
VSM Assessment
Gemba Walks
Problem Solving Results
Leader Self-Assessments
Value Stream Analysis
Per Plan (Monthly)
Lean Activities- P2B Process
Kaizen Events
Kaizen JDI’s
Kaizen Projects
Six Sigma Projects
Lean Tool Belt
Future State Plan
Resource Planning for Action Item List
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only DO

9. Strategic Deployment
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

10. The Model to Lean Transformation
Enterprise Strategy
The Model to Lean Transformation
Annually
Annually- Semi-Annually
Strategic Deployment
Monthly, weekly, Daily
ACT
Strategy Deployment L1
Action Items/Countermeasures
Lean Certification- SME
Kepner-Tregoe Problem Solving
Standardization across plant
Managing Culture
Communicate Business Case- Reason for change
Education/Training C H E K
Fundamentals
Dashboard Metrics
Event Pace
Lean ROI
Cross Training Matrix
Event Participation
Cultural Development
Employee Morale/Leadership Development
Spheres
SD Level 2
Toric SD Level 2 P L A N
Semi-annually
Performance Reviews KPI Board Review
VSM Assessment
Gemba Walks
Problem Solving Results
Leader Self-Assessments
Value Stream Analysis
Per Plan (Monthly)
Lean Activities- P2B Process
Kaizen Events
Kaizen JDI’s
Kaizen Projects
Six Sigma Projects
Lean Tool Belt
Future State Plan
Resource Planning for Action Item List
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only DO

11. Strategic Deployment Process
Inputs to Filter:
FDA VOC
Sales Marketing Target Letters R&D
Business
Strategic
Filter
Catch Ball between GM, staff and ET
Catch Ball between VS Leaders and GM/Staff
Filtered Objectives
Alignment between Site and Enterprise
Alignment between VS and Site
Enterprise Level- Executive Level SD
Site Level- GM and Staff Level SD
Value Stream Level- Middle and Front line Leaders SD
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

12. Value Stream Management
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

13. The Model to Lean Transformation
Enterprise Strategy
The Model to Lean Transformation
Annually
Annually- Semi-Annually
Strategic Deployment
Monthly, weekly, Daily
ACT
Strategy Deployment L1
Action Items/Countermeasures
Lean Certification- SME
Kepner-Tregoe Problem Solving
Standardization across plant
Managing Culture
Communicate Business Case- Reason for change
Education/Training C H E K
Fundamentals
Dashboard Metrics
Event Pace
Lean ROI
Cross Training Matrix
Event Participation
Cultural Development
Employee Morale/Leadership Development
Spheres
SD Level 2
Toric SD Level 2 P L A N
Semi-annually
Performance Reviews KPI Board Review
VSM Assessment
Gemba Walks
Problem Solving Results
Leader Self-Assessments
Value Stream Analysis
Per Plan (Monthly)
Lean Activities- P2B Process
Kaizen Events
Kaizen JDI’s
Kaizen Projects
Six Sigma Projects
Lean Tool Belt
Future State Plan
Resource Planning for Action Item List
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only DO

14. “Value Stream Mapping” A Tool to help ID Waste in the Organization
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only
Traditional Batch and Que Value Stream Map

15. Lean Transformation Roadmap Annual Plan
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

16. 6 | Global Lean Transformation Model | Christian D
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

17. Building People capabilities through rapid improvement improvements
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

18. The Model to Lean Transformation
Enterprise Strategy
The Model to Lean Transformation
Annually
Annually- Semi-Annually
Strategic Deployment
Monthly, weekly, Daily
ACT
Strategy Deployment L1
Action Items/Countermeasures
Lean Certification- SME
Kepner-Tregoe Problem Solving
Standardization across plant
Managing Culture
Communicate Business Case- Reason for change
Education/Training C H E K
Fundamentals
Dashboard Metrics
Event Pace
Lean ROI
Cross Training Matrix
Event Participation
Cultural Development
Employee Morale/Leadership Development
Spheres
SD Level 2
Toric SD Level 2 P L A N
Semi-annually
Performance Reviews KPI Board Review
VSM Assessment
Gemba Walks
Problem Solving Results
Leader Self-Assessments
Value Stream Analysis
Per Plan (Monthly)
Lean Activities- P2B Process
Kaizen Events
Kaizen JDI’s
Kaizen Projects
Six Sigma Projects
Lean Tool Belt
Future State Plan
Resource Planning for Action Item List
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only DO

19. Kaizen or Rapid Improvement Event Process 12 Week Cycle
ID Event
State Lean Tool
expected improvement
Plan event date and
Record on
Event Calendar
Value Stream
Mapping Event
Pre Work- 7 weeks prior to
Event. Establish team,
Develop Charter, ID facilitator, train,
And brainstorm. Hold weekly team
Meetings, and gain approval.
7 weeks prior to event
Event Week- Make
Improvements, PDCA
Event Week
VSA, RIE, VVS, 6-Sigma (DMAIC), 3P (7 Alternatives), A3, TPOC, DOE, Known proven solutions, 6S, Load-Load, Standard Work, Policy Deployment, SMED, TPM, Inventory Reduction, Visual Workplace, Flow Map
Sustainment- Team
monitors, Adjusts,
and sustains
Improvement activities
Cultural, Socio-Technical, and Economic Breakthroughs
4 weeks after event
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

20. Kaizen or Rapid Improvement Event Process 12 Week Cycle
VSA, RIE, VVS, 6-Sigma (DMAIC), 3P (7 Alternatives), A3, TPOC, DOE, Known proven solutions, 6S, Load-Load, Standard Work, Policy Deployment, SMED, TPM, Inventory Reduction, Visual Workplace, Flow Map

21. Rate of development
Number of people in the organization assigned as SME’s
3% of workforce assigned to OPEX
Number of RIE at each location, globally
1 RIE per month for every 100 employees
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

22. Governance
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

23. The Model to Lean Transformation
Enterprise Strategy
The Model to Lean Transformation
Annually
Annually- Semi-Annually
Strategic Deployment
Monthly, weekly, Daily
ACT
Strategy Deployment L1
Action Items/Countermeasures
Lean Certification- SME
Kepner-Tregoe Problem Solving
Standardization across plant
Managing Culture
Communicate Business Case- Reason for change
Education/Training C H E K
Fundamentals
Dashboard Metrics
Event Pace
Lean ROI
Cross Training Matrix
Event Participation
Cultural Development
Employee Morale/Leadership Development
Spheres
SD Level 2
Toric SD Level 2 P L A N
Semi-annually
Performance Reviews KPI Board Review
VSM Assessment
Gemba Walks
Problem Solving Results
Leader Self-Assessments
Value Stream Analysis
Per Plan (Monthly)
Lean Activities- P2B Process
Kaizen Events
Kaizen JDI’s
Kaizen Projects
Six Sigma Projects
Lean Tool Belt
Future State Plan
Resource Planning for Action Item List
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only DO

24. Standard Work Communication Tools
Area of Flow populates its performance hourly
Front Line Leaders populate data daily on the SQDC Communication board
Site Leaders populate the Dashboard monthly.
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only
VS Leaders populate data on the VS Board weekly

25. Leader Standard Work - Senior Leader Immersion Plan
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

26. Leader Standard Work - Leader standard work
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

27. The Model to Lean Transformation
Enterprise Strategy
The Model to Lean Transformation
Annually
Annually- Semi-Annually
Strategic Deployment
Monthly, weekly, Daily
ACT
Strategy Deployment L1
Action Items/Countermeasures
Lean Certification- SME
Kepner-Tregoe Problem Solving
Standardization across plant
Managing Culture
Communicate Business Case- Reason for change
Education/Training C H E K
Fundamentals
Dashboard Metrics
Event Pace
Lean ROI
Cross Training Matrix
Event Participation
Cultural Development
Employee Morale/Leadership Development
Spheres
SD Level 2
Toric SD Level 2 P L A N
Semi-annually
Performance Reviews KPI Board Review
VSM Assessment
Gemba Walks
Problem Solving Results
Leader Self-Assessments
Value Stream Analysis
Per Plan (Monthly)
Lean Activities- P2B Process
Kaizen Events
Kaizen JDI’s
Kaizen Projects
Six Sigma Projects
Lean Tool Belt
Future State Plan
Resource Planning for Action Item List
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only DO

28. P2B Model
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only

29. Questions?
6 | Global Lean Transformation Model | Christian D. Cater | 28 SEP 2016 | For Private Audience Only