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G-G-11
Rapid Process Improvement Rapid Process Improvement Event OverviewEvent Overview
Dewey WardenDewey Warden
G-G-22
What is RPI?What is RPI?
RPI stands for RPI stands for RRapid apid PProcess rocess IImprovementmprovement
RPI supports “continuous improvement”RPI supports “continuous improvement”
Origin of RPI is KaizenOrigin of RPI is Kaizen– ““Kai” means “Take apart”Kai” means “Take apart”
– ““Zen” means “Make it good”Zen” means “Make it good”
G-G-33
Why RPI?Why RPI?
A RPI Event provides focus.A RPI Event provides focus.– On a processOn a process
– On an operationOn an operation
This helps to identify value and wasteThis helps to identify value and waste
G-G-44
Understanding RPIUnderstanding RPI
RPI is a means of getting people to solve problemsRPI is a means of getting people to solve problems
Generate ideasGenerate ideas
Temporary fulltime projectsTemporary fulltime projects
Begin with get-it-done type peopleBegin with get-it-done type people
G-G-55
Understanding RPIUnderstanding RPI
RPI is a means of changing cultureRPI is a means of changing culture
Events must be successfulEvents must be successful
Events must have management supportEvents must have management support
RPI requires the “Right Spirit”RPI requires the “Right Spirit”
G-G-66
Understanding RPIUnderstanding RPI
Use RPI events as building blocksUse RPI events as building blocks– Continuous improvementContinuous improvement
– Changing culturesChanging cultures
– Utilizing value stream mapping and lean toolsUtilizing value stream mapping and lean tools
G-G-77
RPI Fits Our CultureRPI Fits Our Culture
Absolutes of QualityAbsolutes of Quality
Continuous improvementsContinuous improvements
Performance expectationsPerformance expectations
Five-step problem solving processFive-step problem solving process
G-G-88
RPI ToolsRPI Tools
Quick changeoversQuick changeovers
5S’s5S’s
Standardized workStandardized work
Pull productionPull production
KanbanKanban
Total productive maintenanceTotal productive maintenance
G-G-99
Leading an RPI EventLeading an RPI Event
Leadership and a willingness to embrace Leadership and a willingness to embrace change and embrace lean, believe in itchange and embrace lean, believe in it
Be participative and not dictatorialBe participative and not dictatorial
Be fair, firm, assertive and friendlyBe fair, firm, assertive and friendly
Be able to take control when necessaryBe able to take control when necessary
Be willing to be out on the floor when necessaryBe willing to be out on the floor when necessary
G-G-1010
Before the RPI EventBefore the RPI Event
Identify the lean advocateIdentify the lean advocate
Create a current state value stream mapCreate a current state value stream map
Identify opportunities for improvementIdentify opportunities for improvement
Create a future state value stream mapCreate a future state value stream map
Identify RPIsIdentify RPIs
Prioritize the RPIsPrioritize the RPIs
G-G-1111
Create a Current State Value Stream Create a Current State Value Stream MapMap
You might want to videotape your processes and You might want to videotape your processes and complete process observation sheetscomplete process observation sheets– Cycle time analysisCycle time analysis
– Takt time analysisTakt time analysis
– Current manpower requirementsCurrent manpower requirements
G-G-1212
Create a Current State Value Create a Current State Value Stream MapStream Map
Identify materials in the selected areaIdentify materials in the selected area– Average daily usageAverage daily usage
– Replenishment timeReplenishment time
– Current ordering patternsCurrent ordering patterns
– Footprint of current storage spaceFootprint of current storage space
Identify changeover timesIdentify changeover times
G-G-1313
Identify Opportunities for ImprovementIdentify Opportunities for Improvement
ProcessProcess
Kanban pull vs pushKanban pull vs push
Standard work and cycle timeStandard work and cycle time
Techniques to support leanTechniques to support lean
G-G-1414
Create a Future State Value Stream Create a Future State Value Stream MapMap
Draw the future state to Draw the future state to – Eliminate the waste and add value to the processes Eliminate the waste and add value to the processes
– Reduce lead time and inventoryReduce lead time and inventory
G-G-1515
Identify the RPIsIdentify the RPIs
Use the current state to draw the kaizen bursts Use the current state to draw the kaizen bursts or individual projects that would be slotted for or individual projects that would be slotted for RPIs to change from the current to the futureRPIs to change from the current to the future
G-G-1616
Identify RPIsIdentify RPIs
Identify opportunities by recognizing wasteIdentify opportunities by recognizing waste
What is waste?What is waste?– Waste is any element that adds cost without adding value Waste is any element that adds cost without adding value
to the productto the product
G-G-1717
Prioritize the RPIsPrioritize the RPIs
After all the kaizen bursts or RPI’s have been After all the kaizen bursts or RPI’s have been identified while creating the future state VSM identified while creating the future state VSM then it is best to loop the RPI’s and prioritize the then it is best to loop the RPI’s and prioritize the events and begin implementing themevents and begin implementing them
G-G-1818
The RPI EventThe RPI Event
Planning and preparationPlanning and preparation
ImplementationImplementation
Presentation, celebration and evaluation Presentation, celebration and evaluation
G-G-1919
Planning and PreparationPlanning and Preparation
Select an area Select an area – CriteriaCriteria
Too much WIP inventoryToo much WIP inventory
BottlenecksBottlenecks
StoppagesStoppages
MessMess
Activities that occur all over the plantActivities that occur all over the plant
G-G-2020
Planning and PreparationPlanning and Preparation
Select an easy project for your first RPISelect an easy project for your first RPI
It should be visibleIt should be visible
It should have an impactIt should have an impact
It should be operationalIt should be operational
Can it be copied?Can it be copied?
G-G-2121
Planning and PreparationPlanning and Preparation
Select a problem for improvementSelect a problem for improvement– Keep the elimination of waste as the focusKeep the elimination of waste as the focus
– Look at gimba “real things”Look at gimba “real things”The factory, facts and WIPThe factory, facts and WIP
– Ask what, why, how, where, when?Ask what, why, how, where, when?
G-G-2222
Planning and PreparationPlanning and Preparation
Select peopleSelect people– Facilitator Facilitator
The lean advisory team will lead the first RPI eventThe lean advisory team will lead the first RPI event
The company’s lean advocate will lead the second RPI while we The company’s lean advocate will lead the second RPI while we facilitatefacilitate
The company’s lean advocate will lead and facilitate the third RPI The company’s lean advocate will lead and facilitate the third RPI event while we observeevent while we observe
Source: Productivity Press
G-G-2323
Planning and PreparationPlanning and Preparation
Lean advocateLean advocate– Help select team membersHelp select team members
– Help gather information necessary for the eventHelp gather information necessary for the event
– Help prepare for the eventHelp prepare for the event
– Coordinate assignmentsCoordinate assignments
– Compile informationCompile information
– Help get the team ready for the presentation Help get the team ready for the presentation
– Do follow-up and store informationDo follow-up and store information
G-G-2424
Planning and PreparationPlanning and Preparation
Select peopleSelect people– Team leaderTeam leader
LeadershipLeadership
Willingness to embrace change and leanWillingness to embrace change and lean
Be participative and not dictatorialBe participative and not dictatorial
Be fair, firm, assertive and friendlyBe fair, firm, assertive and friendly
Be able to take control when necessaryBe able to take control when necessary
Be willing to be out on the floor when necessaryBe willing to be out on the floor when necessary
G-G-2525
Planning and PreparationPlanning and Preparation
Team leader responsibilitiesTeam leader responsibilities– Help select team membersHelp select team members
– Help gather information necessary for the eventHelp gather information necessary for the event
– Help prepare for the eventHelp prepare for the event
– Coordinate assignmentsCoordinate assignments
– Compile informationCompile information
– Help get the team ready for the presentation Help get the team ready for the presentation
– Do follow-up and store informationDo follow-up and store information
G-G-2626
Planning and PreparationPlanning and Preparation
Select team membersSelect team members– Should have about six but no more than twelveShould have about six but no more than twelve
– Include operators if possibleInclude operators if possible
– Half should be from outside the areaHalf should be from outside the area
– Maintenance add valuable expertiseMaintenance add valuable expertise
– Team playersTeam players
– Get-it-done type people not naysayersGet-it-done type people not naysayers
G-G-2727
Planning and PreparationPlanning and Preparation
Train the teamTrain the team– Train them to see the value stream mapTrain them to see the value stream map
This will help everybody to see and understand the “big picture”, This will help everybody to see and understand the “big picture”, identify waste, identify what needs to be done and get buy-in into identify waste, identify what needs to be done and get buy-in into the overall strategy.the overall strategy.
– Train them on overall lean concepts to eliminate wasteTrain them on overall lean concepts to eliminate waste
G-G-2828
Planning and PreparationPlanning and Preparation
Train the teamTrain the team– Train them on how to do the 5S’sTrain them on how to do the 5S’s
There has never been a successful implementation of lean without There has never been a successful implementation of lean without organizing the area.organizing the area.
G-G-2929
ImplementationImplementation
Understand the current situationUnderstand the current situation
Observe and gather your dataObserve and gather your data
Identify the improvementsIdentify the improvements
Test the improvementsTest the improvements
Implement the improvementsImplement the improvements
G-G-3030
ImplementationImplementation
Conduct the specific training needed for the Conduct the specific training needed for the event itself.event itself.– Pull productionPull production
– KanbanKanban
– Standardized workStandardized work
– Total productive maintenanceTotal productive maintenance
– Quick changeoversQuick changeovers
G-G-3131
Presentation, Celebration and Presentation, Celebration and EvaluationEvaluation
Prepare a presentationPrepare a presentation
Rehearse the presentationRehearse the presentation
Present the resultsPresent the results
Celebrate the resultsCelebrate the results
Follow-upFollow-up