Continuous Improvement (CI) Overview A quick review of principles, methodology, and tools

1. Continuous Improvement (CI) OverviewA quick review of principles, methodology, and tools

2. Learning Objective • Provide Kaizen event team members with basic knowledge of CI principles, methodology, and tools to assist in their improvement project.

3. 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

4. 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

5. Why Focus on Process?

6. Process Improvement Benefits

7. 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.

8. Why CI? CI IMPROVES RESULTS AND REDUCES COSTS!

9. What it's all about • Meals Per Hour • Meals Per Hour.mp4

10. Kaizen Event Example

11. CI Principles Performance Excellence Culture

12. CI Methodology Challenge the status quo Validate assumptions Following the Lean methodology to ensure knowledge creation and continuous improvement

13. 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

14. Transportation Inventory Motion Waiting Overproduction Overprocessing Defects * Underutilized Staff Creativity Tim Woods 7 Wastes

15. 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.

16. Poka Yoke – Error Proofing

17. 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.

18. Visual Management

19. 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.

20. Swim Lane Map Kaizen events use swim lane maps to document the current and future process

21. 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.

22. Cause and Effect Analysis • Fishbone diagram or Ishikawa

23. 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

24. 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) # # # # # #

25. Action Plan

26. 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