Kaizen Leader Training: Improving the Practice-to ... · • Blended training model effective and efficient way to train kaizen leaders • Classroom session should be interactive

Kaizen Leader Training: Improving the Practice-to-Performance Ratio

Whitney Mantonya Collaborative Lean Solutions Ellen Milnes MoreSteam.com

Sponsored by:

© MoreSteam.com 2016

• Process Improvement Training &

Technology

• Trained 500,000+ Lean Six Sigma

professionals

• Served over 50% of the Fortune 500

• Courses reviewed and approved by

ASQ and PMI

• Academic Partnerships with The

Ohio State University, University of

Notre Dame, California Polytechnic

University, and George Washington

University

MoreSteam.com

3

Select Customers:


http://welcome.hp.com/country/us/en/welcome.html


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© MoreSteam.com 2016 5

63:1 The ratio of practice to play


Answers to the first two survey questions (training drivers and most important skills) were collected during a series of one day benchmarking conferences conducted in the US and Europe during 2014 and 2015.

Answers to questions about eLearning effectiveness were collected from MoreSteam’s larger enterprise customers in a survey conducted in September of 2015. Respondents include IBM, HP, Hertz, AB-InBev, Tyco, Honeywell, PPG, Eli Lilly, Ohio State, Emerson Network Power, Nationwide Insurance, and Cardinal Health.

6

Data was collected from two sources.


8

22

32

35

64

Complex Data Analysis Tools

Team Leadership

Simple Data Analysis Tools

Lean Methods

Skill at Implementing Change

What skills/tools are most important to you and your people?

Data collected over last 12 months

7


3

11

12

13

33

Something Else

Instructor Time/Cost

Travel Cost

Training Flexibility

Training Effectiveness

Which driver has the most influence on your training design?

Data collected over last 12 months

8


How effective is your blended training model compared

to the training model you used previously?

Std. Deviation 35.7%

N = 29

0% 25% 50%

39.5% Better Mean

Median 30% Better

9


10

Some things don’t need much design work…


11

Some do…


12


0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0% 90.0% 100.0%

Classroom Lecture

Physical Sims (catapult, Sigma Station)

Online Sims (SigmaBrew, InBox)

Study Halls

One-on-one Coaching

Project Work

Learning Activities Used in Blended Model – Beyond eLearning

All responses: n=29

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0.0% 20.0% 40.0% 60.0% 80.0% 100.0%

Classroom Lecture

Physical Sims (catapult, Sigma Station)

Online Sims (SigmaBrew, InBox)

Study Halls

One-on-one Coaching

Project Work

Learning Activities Used in Blended Model

Highest Improvement

Lowest Improvement

Comparison of 9 Worst vs. 8 Best

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What are the most important success factors for your training model?

0 1 2 3 4

Leadership Support for Training Time

Reporting

Scheduled Weekly/Monthly meetings

Realistic Simulation/Practice

Structured timeline and deadlines

Success Factors

From responses with greatest improvement


0 1 2 3 4 5 6 7 8

Presentation Version of Content

More Practice, Shorter Cycles ofApplication

In-Person Study Hall, Workshop

Communicate Real Success Stories, CaseStudy

Realign Content - Quick Improvement

More Simulation

Do-Over

If you had a do-over on your blended learning design,

what would you do differently?

From responses with least improvement


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Bloom’s Taxonomy

Bloom's Taxonomy (Revised)

Create

Evaluate

Analyze

Apply

Understand

Remember


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Creating

Evaluating

Analyzing

Applying

Remembering

Understanding

Passive

Active Dynamic

Complex

Open-Ended

Structured

Simple, Linear

Close-ended

Learning Activities Bloom’s Taxonomy


19

Complex

Open-Ended

Close-Ended

Simple

Map Your

Learning Activities


20

Complex

Open-Ended

Close-Ended

Simple

Card

Drop

Dice

Quiz Story Problem

Quiz with Data

Case

Study

Lean

Process

Sim

(InBox)

Project

Work

Catapult

SigmaBrew

DMAIC

Drag

& Drop


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Key Ingredients:

Key Methods:

Realistic Simulation

More Components

Clear Expectations,

Structure, Follow-up,

Leadership Support


Example: Kaizen Leader Training

What Is Kaizen?

WA

ST

E Measure

Analyze

Improve

Control

Define Kaizen event

Quick Hit

VA

RIA

TIO

N

Problem Solving Leveraging Data Analysis

Rapid Implementation of Simple, Visible Solutions

Small Improvements to Individual Daily Work

GB/BB Project

Continuous Improvement Continuum

Kaizen: the Rugby of Process Improvement

Collaborative Lean Solutions

Guiding Principles of Kaizen Training Design

• Participants need to know more than just lean tools

• Use InBox simulation as a Kaizen event

• Provide multiple opportunities to practice facilitating the common Kaizen activities

STEP 1: BUILDING THE KAIZEN MODEL


Kaizen Activities

Pre-event Prep ( 8-12 hrs)

Event Week- 5 days

Follow up actions- 15 days


Kaizen Event Flow – 4 ½ days

Day 1 D/M

•Team Training

•Charter/SIPOC Review

•VSM/Process Mapping

•NVA/Pain Point Identification

Day 2 A

•Root Cause Analysis

•Brainstorm and Select Solutions

•Future State Mapping

Day 3

I

•Kaizen Week Action Plan

•Midweek pitchout preparation and presentation

•Pilot and/or Implementation of Solutions

Day 4

I

•Implementation of Solutions

Day 5

C

•30 day action plan

•Final Financial Calculations

•Final Pitchout Preparation and Presentation


Certification Requirements

• Completion of on-line and classroom training curriculum

Training

• Participate/observe a minimum of 1 kaizen event

Observation

• Lead 2 events

Event Lead


Considerations

• Timing of participation

– Prior to training

– Sponsored event week

• Coaching support

– Experienced resources to support

– Leverage short term external support to build capability

STEP 2: BUILDING A BLENDED PROGRAM


Training Goals

Tool Knowledge

• Commonly used lean tools

• What they tell you

• When they are used

Kaizen Execution

• Flow of the Kaizen event

• Picking the right tools for the problem at hand

• Sequence of activities

Facilitation

• Build confidence in facilitation skills

• Provide multiple opportunities to facilitate and observe others in the facilitation of specific tools


Training Design

• Kaizen Model

• Project Definition

• Metrics

• Lean Tools

On-line Curriculum

(22 hrs)

• Brief tool review with practice exercises

• Leverage simulation as a proxy for actual Kaizen event

• Provide multiple opportunities to practice facilitation

Classroom Session

(2 days)


Classroom Sessions: Keeping it Interactive


Tennis Ball: Setting the Stage

Image courtesy of http://wardrounds.northwestern.edu


Shapes: Build understanding of the impact of lean tools


Standard Pig: Demonstrating Impact of Standard Work

Round 1

• Using the grid provided draw a side profile of a pig, centered on the page

• Make sure the pig’s head is facing left

• Pig must be large enough so that a piece of it is in every box EXCEPT the top right

• You have 2 minutes to draw your pig- we will post each one on the wall

Round 2:

• Use distributed work instructions to draw a pig on the grid


Round 3:

• Use newly distributed work instructions to draw a pig on the grid



InBox: Experience Facilitating a Kaizen Event


Piloting the Program


Pilot Lessons Learned

• Blended training model effective and efficient way to train kaizen leaders

• Classroom session should be interactive and provide participants with multiple opportunities to practice facilitation

• Demand for training should be balanced with ability to provide coaching support and opportunities to observe or co-lead prior to independently leading kaizen events.

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Kaizen Leader Training: Improving the Practice-to ... · • Blended training model effective and efficient way to train kaizen leaders • Classroom session should be interactive