Rapid Process Improvement Event OverviewDewey Warden

What is RPI?RPI stands for Rapid Process ImprovementRPI supports continuous improvementOrigin of RPI is KaizenKai means Take apartZen means Make it good

Why RPI?A RPI Event provides focus.On a processOn an operationThis helps to identify value and waste

Understanding RPIRPI is a means of getting people to solve problemsGenerate ideasTemporary fulltime projectsBegin with get-it-done type people

Understanding RPIRPI is a means of changing cultureEvents must be successfulEvents must have management supportRPI requires the Right Spirit

Understanding RPIUse RPI events as building blocksContinuous improvementChanging culturesUtilizing value stream mapping and lean tools

RPI Fits Our CultureAbsolutes of QualityContinuous improvementsPerformance expectationsFive-step problem solving process

RPI ToolsQuick changeovers5SsStandardized workPull productionKanbanTotal productive maintenance

Leading an RPI EventLeadership and a willingness to embrace change and embrace lean, believe in itBe participative and not dictatorialBe fair, firm, assertive and friendlyBe able to take control when necessaryBe willing to be out on the floor when necessary

Before the RPI EventIdentify the lean advocateCreate a current state value stream mapIdentify opportunities for improvementCreate a future state value stream mapIdentify RPIsPrioritize the RPIs

Create a Current State Value Stream Map

You might want to videotape your processes and complete process observation sheetsCycle time analysisTakt time analysisCurrent manpower requirements

Create a Current State Value Stream MapIdentify materials in the selected areaAverage daily usageReplenishment timeCurrent ordering patternsFootprint of current storage spaceIdentify changeover times

Identify Opportunities for ImprovementProcessKanban pull vs pushStandard work and cycle timeTechniques to support lean

Create a Future State Value Stream MapDraw the future state to Eliminate the waste and add value to the processes Reduce lead time and inventory

Identify the RPIsUse the current state to draw the kaizen bursts or individual projects that would be slotted for RPIs to change from the current to the future

Identify RPIsIdentify opportunities by recognizing wasteWhat is waste?Waste is any element that adds cost without adding value to the product

Prioritize the RPIsAfter all the kaizen bursts or RPIs have been identified while creating the future state VSM then it is best to loop the RPIs and prioritize the events and begin implementing them

The RPI EventPlanning and preparationImplementationPresentation, celebration and evaluation

Planning and PreparationSelect an area CriteriaToo much WIP inventoryBottlenecksStoppagesMessActivities that occur all over the plant

Planning and PreparationSelect an easy project for your first RPIIt should be visibleIt should have an impactIt should be operationalCan it be copied?

Planning and PreparationSelect a problem for improvementKeep the elimination of waste as the focusLook at gimba real thingsThe factory, facts and WIPAsk what, why, how, where, when?

Planning and PreparationSelect peopleFacilitator The lean advisory team will lead the first RPI eventThe companys lean advocate will lead the second RPI while we facilitateThe companys lean advocate will lead and facilitate the third RPI event while we observeSource: Productivity Press

Planning and PreparationLean advocateHelp select team membersHelp gather information necessary for the eventHelp prepare for the eventCoordinate assignmentsCompile informationHelp get the team ready for the presentation Do follow-up and store information

Planning and PreparationSelect peopleTeam leaderLeadershipWillingness to embrace change and leanBe participative and not dictatorialBe fair, firm, assertive and friendlyBe able to take control when necessaryBe willing to be out on the floor when necessary

Planning and PreparationTeam leader responsibilitiesHelp select team membersHelp gather information necessary for the eventHelp prepare for the eventCoordinate assignmentsCompile informationHelp get the team ready for the presentation Do follow-up and store information

Planning and PreparationSelect team membersShould have about six but no more than twelveInclude operators if possibleHalf should be from outside the areaMaintenance add valuable expertiseTeam playersGet-it-done type people not naysayers

Planning and PreparationTrain the teamTrain them to see the value stream mapThis will help everybody to see and understand the big picture, identify waste, identify what needs to be done and get buy-in into the overall strategy.Train them on overall lean concepts to eliminate waste

Planning and PreparationTrain the teamTrain them on how to do the 5SsThere has never been a successful implementation of lean without organizing the area.

ImplementationUnderstand the current situationObserve and gather your dataIdentify the improvementsTest the improvementsImplement the improvements

ImplementationConduct the specific training needed for the event itself.Pull productionKanbanStandardized workTotal productive maintenanceQuick changeovers

Presentation, Celebration and EvaluationPrepare a presentationRehearse the presentationPresent the resultsCelebrate the resultsFollow-up