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Continuous Improvement (CI) Overview A quick review of principles, methodology, and tools. Learning Objective. Provide Kaizen event team members with basic knowledge of CI principles, methodology, and tools to assist in their improvement project. What is Process Improvement?.
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Continuous Improvement (CI) OverviewA quick review of principles, methodology, and tools
Learning Objective • Provide Kaizen event team members with basic knowledge of CI principles, methodology, and tools to assist in their improvement project.
What is Process Improvement? • Process – actions/steps taken to produce a service, product or result (How) • Improvement – enhancing value or excellence • Process Improvement – identifying, analyzing, and improving the steps we take to produce a service, product or result Quality + Timeliness + Costs = Productivity/Value
It’s about Process Simplification • Eliminate tasks that do not add value • Make things easy and intuitive for customers and staff • Automate repetitive tasks so that employees can devote time to providing customer value and planning and implementing other improvements
What is CI? A time-tested method and set of tools to help us understand: • What adds value to our customers • How work gets done currently • How we can identify root causes of problems • What an “ideal / no waste” process looks like • How we can improve performance CI embodies a way of thinking and acting to continually improve services and enhance customer value.
Why CI? CI IMPROVES RESULTS AND REDUCES COSTS!
What it's all about • Meals Per Hour • Meals Per Hour.mp4
CI Principles Performance Excellence Culture
CI Methodology Challenge the status quo Validate assumptions Following the Lean methodology to ensure knowledge creation and continuous improvement
CI Concepts and Tools • 7 Wastes • 5S • Poka Yoke • Visual Management • Kaizen (Kaizen Event) • Problem solving tools • 5 Whys • Cause and Effect Analysis • Standard Work
Transportation Inventory Motion Waiting Overproduction Overprocessing Defects * Underutilized Staff Creativity Tim Woods 7 Wastes
5S • Sort • Set In Order • Shine • Standardize • Sustain 6th “S” for “Safety” A simple method for creating a clean, safe, orderly, high performance work environment.
Visual Management (2S) A communication device that tells, at a glance, how work should be done. • Where items belong • How many items • Standard procedure • Work in progress There is only one place to put each item.
Kaizen and Kaizen Events A Kaizen event is a facilitated, rapid improvement event that engages the creativity of employees to remove waste from a process.
Swim Lane Map Kaizen events use swim lane maps to document the current and future process
5 Whys • 5 Whys is a SIMPLE but POWERFUL technique for uncovering the root cause of a problem when you lack data regarding why the problem is occurring. • If we don’t solve problems at the level of the root cause, we risk the same problem resurfacing in the future.
Cause and Effect Analysis • Fishbone diagram or Ishikawa
Standard Work The safest, highest quality, and most efficient way to perform a task or process. • Focuses on helping the employee be successful • Reduces variation and increases consistency • Improvements cannot be sustained without it “Where there is no standard, there can be no Kaizen.” TaiichiOhno, Vice-President Toyota Motor Company
Recommendation Prioritization IMPACT high impact + high difficulty Top Recommendations (high impact + low difficulty) # # # # DIFFICULTY # # low impact + high difficulty Low Hanging Fruit (low impact + low difficulty) # # # # # #
For More Information • Minnesota Office of Continuous Improvement • Dept. of Administration, State of Minnesota • MN.gov/CI | Lean@state.mn.us • Mary Jo Caldwell |Director • Office: 651.201.2560 | Mary.Jo.Caldwell@state.mn.us • Cristine Leavitt | Trainer and Facilitator • Office: 651.201.2567 | Cristine.Leavitt@state.mn.us