Effective Organizational Change is a Two Minute Drill University of Toledo Senior Design Class

2 0 0 Two Minute DrillTM

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Effective Organizational Change is a Two Minute

Drill

University of ToledoSenior Design Class

“This gentleman, is a football “ … Vince Lombardi


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• Introduction to IET, Inc.

• Organizational Change is a Two Minute Drill

• Production Launch Case Study

• Individual Achievement Award (Drawing)

• Breakout Session

Agenda“This ladies and gentleman, is a football “ … Tim Stansfield


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Industrial Engineering Technologies (IET, Inc.) is an industrial engineering consulting firm offering quality engineering services to industrial, commercial, governmental, health care and food service clients throughout the nation.

Professional Services“A winning effort begins with preparation “ … Joe Gibbs


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x x x xx xIET Services

• Productivity & Work Measurement• Capacity Planning• New Manufacturing Integration• Indirect Labor Analysis & Design• Total Value Analysis• Process Flow Analysis & Design

“Nobody in football should be called a genius, a genius as a guy like Norman Einstein “ … Joe Theisman


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“Football is like life; it requires perseverance, self-denial, hard work, sacrifice, dedication and respect for authority.”

… Vince Lombardi


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What Are the Characteristics of Successful Organizational Improvement?

• Requires a leader• The target results must be understood• You must plan for challenges• Everyone must be committed

“This ladies and gentleman, is a football “ … Tim Stansfield


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What are the Characteristics of Successful Organizational Improvement?

• The right people must be involved• Must execute the plan• Must be sure the improvement sticks• We should learn from the process

“A winning effort begins with preparation” …Joe gibbs


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What Are the Characteristics of A Two-minute Drill?

• One quarterback must control the game

• Winning must be clearly defined

• You must know your opponents

• There must be focus and sense of urgency

“In the succesful organization, no detail is too small to escape attention” …Lou Holtz


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What Are the Characteristics of a Two-Minute Drill?

• Use the right plays and the right players• Execute and adjust• Ensure the win and celebrate• Learn from game experience

“The secret to winning is constant, consistent management” …Tom Landry


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x x x xx xOne Quarterback Must Control the Game

Organizational improvement begins with a good quarterback

• Must be a leader• Respected and smart• Know the game• Have vision• Organized• Effective communication skills

“ Sure, luck means a lot in football. Not having a good quarterback is bad luck.“ … Don Shula


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x x x xx xOne Quarterback Must Control the Game

The leader is not the coach

• The leader must be on the field• The leader must take a few hits• The leader cannot simply call the plays• The leader must execute the plays• The leader cannot send the trainer out on the

field

“ Nobody in football should be called a genius, a genius is a guy like Norman Einstein … Joe Theisman


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x x x xx xWinning Must Be Clearly Defined

What do we need out of this improvement initiative to win?

• Driven by the current score• Don’t go for the touchdown when you need a

field goal• What are the current conditions or rules?• Does everyone know the score?• Do what we have practiced

“How you respond to the challenge will determine what you become after the game, whether you are a winner or a loser.“ … Lou Holtz


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x x x xx xYou Must Know Your Opponents

In football, these are called the match-ups

• Do some initial scouting• Look at your competitors• Look at yourself• Look at your team• Look at your organization• Look at your situation

“ The man who complains about the way the ball bounces is likely the one who dropped it.“ … Lou Holtz


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x x x xx xThere Must Be Focus and Sense of Urgency

• Every member of the TMD must recognize the project urgency

• Specific timetable• Critical situation• Requires specific concentration• Avoid the extremes

– Nothing is important– Everything is important

“If you aren’t fired with enthusiasm, you’ll be fired with enthusiasm.“ … Vince Lombardi


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x x x xx xRequires the Right Plays and Players

• Each play is designed with a specific outcome• Specific blocking and tackling• Appropriate receivers• Appropriate running backs• Eleven players (The proper number of players)• Everyone knows their role!!!

“The secret of winning football games is working more as a team, less as individuals. I play not my 11 best, but my best 11.“ … Knute Rockne


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x x x xx xExecute and Adjust

• Monitor the game scoreboard• Keep all players aware of the clock• Move the ball, control the clock• Make necessary adjustments• Respond to setbacks• Don’t panic and throw the bomb

“Setting the goal is not the main thing. It is deciding how you will go about achieving it and staying with the plan.“ … Tom Landry


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x x x xx xEnsure the Win and Celebrate

• This is a win• Ensure the win sticks (plan)• Opportunity for public affirmation• The whole team is included in the celebration

“Winning is only half of it. Having fun winning is the other half.“ … Bum Phillips


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x x x xx xLearn From the Game Experience

• Learn from experience• Summarize best practices• Add the game films to the next practice• Identify key players for future TMD’s

“When a team outgrows individual performance and learns team confidence, excellence becomes a reality” …Joe Paterno


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x x x xx xIndividual Achievement Awards

“The toughest part of playing quarterback is the amount of

information that must be processed in a few seconds while all hell is breaking loose around

him.” … Troy Aikman


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The Case Study

Major tier one automotive supplier to General Motors

Manufactured interior door panels for a new vehicle

• 1400 Vehicle Sets Per Day• Four Doors• Delivered JIT (Assembly plant was about 200 miles

away)• Wide range of options

“The secret to winning is constant, consistent management “ … Tom Landry


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• 60 million dollar plant doing well• 40 million dollars in business leaving• 80 million dollars in new business (one program)

• New capital• New facilities• New tooling• New processes• New manufacturing team

How it Began“In the successful organization, no detail is too small to escape attention.“ … Lou Holtz


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• Building about 1100 car sets per day• 200 car sets per day into rework warehouse• High process variation• No ability to build finished goods bank

Production Situation“We didn’t lose the game, we just ran out of time“ … Vince Lombardi


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1. Meet customer demands with whatever it takes (touchdown)

2. Drive the plant towards profitability (close out the game)

Item number one must be completed before we even think about tackling item number two.

The Mission“People who work together will win, whether it be against complex football defenses, or the problems of modern society.“ … Vince Lombardi


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x x x xx xThe Flaw

The manufacturing team: given autonomy to develop a state-of-the-art lean manufacturing system.

•We had a coaching staff•But no clear quarterback•We had the trainers on the field

“Don’t give up at half time. Concentrate on winning the second half.“ … Paul “Bear” Bryant


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•Facilities– New construction, paint, floors, break room,

etc. – Designed by architects and facility engineers

Had some of the plays in the play book

“Pre-game talk is way over-rated. I think fans think that things we say in the locker room makes a difference. It doesn’t. Its how they prepare and were we ready to play.“ … Barry Alvarez

The Flaw (continued)


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x x x xx xThe Flaw (continued)

•Equipment– All new equipment, conveyors, robots, automation

to ensure minimal labor requirements– No history of proven performance in existing

plants (didn’t know the plays)– Designed and built by product and process

engineers (wrong players)– Specified and installed by optimistic equipment

suppliers and managers

“If anything goes bad, I did it. If anything goes semi-good, then we did it. If anything goes really good, then you did it. That’s all it takes to get people to win football games.“ … Paul “Bear” Bryant


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• Manufacturing system design– Autonomous work cells with integrated job

rotation– Designed by manufacturing personnel and the

management team– No overall material flow plan (did not execute)– Labor requirements were optimistically

estimated

The Flaw (continued)“I think everyone should experience defeat at least once during their career. You learn a lot from it.“ … Lou Holtz


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• Manufacturing system design (cont.)– No job instructions / standards / line

balance / process variation plan– No inventory– No realistic picture for process capability– No plan for production loss

The Flaw (continued)“When a team outgrows individual performance and learns team confidence, excellence becomes a reality.“ … Joe Paterno


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• Manufacturing system design (cont.)

Did not practice the playsDid not execute the playsDid not have the right players on the field

The Flaw (continued)“You play the way you practice.“ … Pop Warner


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IET executed their own two minute drill

Action“Don’t tell me how rocky the sea is. Just bring the ship in.“ … Lou Holtz


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• Get data to make decisions based on facts• Develop a statistical model of what is happening on

the floor (score card)• Simplify flow and handling• Adjust inventories / strategy• Line balance / simplify assignments• Performance tracking / goal setting• Attack areas of impact• Be realistic about capabilities (use the data)• Develop timing for cost improvement activities

Action“It’s not the will to win, but the will to prepare to win that makes a difference.“ … Paul “Bear” Bryant


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The good news

The bad news

Results

• Customer demands were met in two weeks

• Production costs were contained within about two months

• Losses were in the millions and were continuing

• Plant reputation was irreparably damaged with the customer

“I’m not into winning games. I’m into winning championships.“ … Bill Parcells


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• Production launches should be run like a TMD

• All organizational change initiatives require a quarterback

• This is a critical situation

• The team must have a sense of urgency

What Was Learned“A winning effort begins with preparation “ … Joe Gibbs


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• One Quarterback• Define Winning• Know Your Opponents• Focus and Sense of Urgency• The Right Plays and Players• Execute and Adjust• Win and Celebrate• Learn

Improvement Characteristics (TMD)“You play the way you practice” …Pop Warner


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Individual Achievement Awards

What Was Learned“If it doesn’t matter who wins, how come they keep score?“ … Vince Lombardi


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Break-out Sessions1. Choose a quarterback

What Was Learned“The toughest part of playing quarterback is the amount of information that must be processed in a few seconds while all hell is breaking loose around him.“ … Troy Aikman

2. Each player (including the quarterback) is to name an organizational change that was successful (One sentence)

3. List five reasons for success

4. List three activities that could have improved success


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Break-out Sessions

5. Present to your huddle (One minute each)

What Was Learned“The key to his success? He’s just faster than the guys who are chasing him.“ … Barry Switzer

7. Quarterback is to stand up and present

6. Summarize the top reason for success and the top reason for failure


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“When you stay with the team and work hard, good things happen.”

… Tom Amstutz

What was Learned

Documents

Effective Organizational Change is a Two Minute Drill University of Toledo Senior Design Class