towards manufacturing...beliefs and systems drive behaviour principles inform ideal behaviour shingo...
TRANSCRIPT
Ailsa Carson
Partner
Towards
World Class
Manufacturing
Summer Webinar Series
18 June, 2020© S A Partners
About S A Partners
Thought Leadership
S A Partners Shingo Prize Winning Publications
18 June, 2020© S A Partners
Workshops & Visits to the World’s Best Companies
BEST PRACTICE VISITS SHINGO WORKSHOPS MASTERCLASS
THE ESSENCE OF EXCELLENCE
3 DAY EXECUTIVE COURSE
A FOUNDATION OF
OPERATIONAL EXCELLENCE
2 DAY WORKSHOP
TPM
18 June, 2020© S A Partners
Some of our HOST companies
18 June, 2020© S A Partners
Why Pursue World Class?
Quality Price Delivery Reliability Flexibility Innovation
World Class companies demonstrate best practice in:
18 June, 2020© S A Partners
Why Pursue World Class?
18 June, 2020© S A Partners
Why Pursue World Class?
Challenge
your
perceptions
18 June, 2020© S A Partners
These 10 ‘Insights’ have been inspired by:
S A Partners
Enterprise Excellence ModelThe SHINGO Model
1. Purpose
S A PartnersEnterprise Excellence Model
18 June, 2020© S A Partners
1. Clearly Defined Purpose
► Why you exist?
► Clarity of Vision
► Owned & understood
► Your True North
S A Partners
Enterprise Excellence Model
18 June, 2020© S A Partners
Simon Sinek – Why? JFK & The Janitor
Purpose
18 June, 2020© S A Partners
History Wall at Altro Floors Combining History & Forward Planning at SAFRAN
History Walls
18 June, 2020© S A Partners
Burning Platform
18 June, 2020© S A Partners
From Burning Platform to Burning Ambition
18 June, 2020© S A Partners
Whose Vision Statement is:
“To Make People Happy”
Use the Question tab - First right answer will win a copy
of the Essence of Excellence or one of our other
Award-Winning Books
Quick Quiz
2.
Strategy
Deployment
S A PartnersEnterprise Excellence Model
18 June, 2020© S A Partners
2. Strategy Deployment
Are we winning or losing?
Each person must have simple & compelling goals that connect daily activities to organizational outcomes.
They must see how accomplishing their goals affects the ability of the organization to meet its goals
This enables us all to focus on a clear objective – what do we need to do today to improve.
It is the what & Why of the journey
Source: Hines & Butterworth – The Essence of Excellence
► Yellow Boards at Vale Group, Clydach
18 June, 2020© S A Partners
► Simple
► Tiered
► Visual
► Engaging
Hoshin (X-Matrix)
18 June, 2020© S A Partners
Hoshin Matrix @ Princes Foods - Belvedere
18 June, 2020© S A Partners
Operational Excellence Roadmap at Crowcon
18 June, 2020© S A Partners
Change Management – Governance of Change
3.
Systems Thinking
S A PartnersEnterprise Excellence Model
18 June, 2020© S A Partners
► Ideal Results Require Ideal Behaviour
► Beliefs and Systems Drive Behaviour
► Principles inform Ideal Behaviour
SHINGO SYSTEMS THINKING The Shingo Model & Guiding Principles
3. Systems Thinking
Download the Webinar:
The Shingo Model
https://sapartners.com/category/resources/
People
Process
Purpose
18 June, 2020© S A Partners
► Ideal Results Require Ideal Behaviour
► Beliefs and Systems Drive Behaviour
► Principles inform Ideal Behaviour
Three Insights The Shingo Guiding Principles
2. Systems Thinking
RESULTSBEHAVIOURSSYSTEMS
18 June, 2020© S A Partners
► Behavioural & Strategy Deployment
► Continuous Improvement
► Learning & Development
► Leader Standard Work
Which Systems?
Be Scilled Framework
S A Partners LLP
18 June, 2020© S A Partners
► Toyota House – CI System
► World Class Manufacturing – 10 Pillars
Other Systems
18 June, 2020© S A Partners
► Toyota House – CI System
► World Class Manufacturing – 10 Pillars
Other Systems
4.
Employee
Engagement
S A PartnersEnterprise Excellence Model
18 June, 2020© S A Partners
► What separates the great from the merely good? The
answer lies not in what you see or the tools people
use, but in the feel, the pure essence of these
organisations. It is the mind-set, the language, the
confidence and the sheer passion for excellence.
► Peter Hines & Chris Butterworth
The Essence of Excellence 2019
Mindset & Language
18 June, 2020© S A Partners
Understanding Ideal Behaviours
18 June, 2020© S A Partners
Behavioural Standards at VALE - Clydach
18 June, 2020© S A Partners
► Measuring Engagement at HAPPY
► Measuring Engagement at CROWCON
Employee Engagement
► Measuring Engagement at HAPPY
Employee Net Promoter Score: How likely are you to recommend this company as a place to work?
18 June, 2020© S A Partners
Behaviours & Micro-Behaviorus
5.Continuous
ImprovementSystem
S A PartnersEnterprise Excellence Model
18 June, 2020© S A Partners
Characteristics of Good CI (Source: Princes Foods)
18 June, 2020© S A Partners
Source: Worldwide Fruit, Spalding Source: Cummins, Daventry
Continuous Improvement – Ideas Programmes
18 June, 2020© S A Partners
► High number of ideas per person
► A high speed of response
► A high close out rate
► Refreshed Regularly
Ideas Programmes
18 June, 2020© S A Partners
► Five S
► Kaizen
► Kanban
► Value Stream Mapping
► OEE
► TPM
► Standardised Work
► Problem Solving
Deploying CI Tools
18 June, 2020© S A Partners
► Fundamental to any organization
► Far reaching implications
► Essential
Five S
5S
1. Sort
2. Set in Order
3. Shine4.
Standardise
5. Sustain
6.
Customer
Focus
18 June, 2020© S A Partners
► Know who your customer is and what they are
buying. More importantly understand what it is
they value.
6. Customer Focus
18 June, 2020© S A Partners
“Every
Customer
interaction
is a
kaizen
opportunity”
Jim Womack
6. Customer Focus
18 June, 2020© S A Partners
Voice of the Customer
7.
Leader Standard Work
S A PartnersEnterprise Excellence Model
18 June, 2020© S A Partners
Be Scilled Framework
S A Partners LLP
7. Leader Standard Work
Download the Webinar:
Leader Standard Work
https://sapartners.com/category/resources/
18 June, 2020© S A Partners
A culture of Continuous Improvement requires an
engaging organization where leaders at all levels spend
time at the workplace checking that improvement is
happening and recognizing and coaching people..
Peter Hines & Chris Butterworth
Essence of Excellence 2019
GEMBA WALKS
► Repeated regularly
► Leadership (not just CI)
► All Areas
► Tiered Accountability
Gemba Walks
18 June, 2020© S A Partners
► Repeated regularly
► Leadership (not just CI)
► All Areas
► Tiered Accountability
Gemba Walks
“Go See, Ask Why, Show Respect”
Fujio Cho
18 June, 2020© S A Partners
► Daily Gemba
► Different System each day:
• Health & Safety
• Standard Work
• Quality
• Customer
• Five S
► Observational & Consultative
Gemba Walks
8.
Learning &
Development
S A PartnersEnterprise Excellence Model
18 June, 2020© S A Partners
“An organization that is continuously expanding its capacity to create its future … the organization that will truly excel will
be the those that discover how to tap people’s commitment and capacity to learn at all levels in an organization.
Peter Senge, The Fifth Discipline pp 4&14
Learning & Development
18 June, 2020© S A Partners
Key Challenges
• Learning & Development seen as a cost
• Generally under-resourced
• HRs responsibility (not the individual or line manager)
To create a learning organization we must:
• Promote a Learning culture – understood by the entire organization
• Share knowledge & learning across functions & geographies
• Manage on the job-learning
• Inspire – self-promoted learning
• Investment is a key business ratio
The Learning Organisation
18 June, 2020© S A Partners
• Highly Visual
• Source: Thermo Fisher Leader
Skills Matrix
• The Essence of Excellence p. 168
SC member
Str
ate
gic
Pla
nn
ing
X
-
Matr
ix
Str
ate
gic
Pla
nn
ing
-
Str
ate
gic
A3
Dail
y M
an
ag
em
en
t
Bo
ard
s
Ab
ilit
y t
o i
den
tify
an
d
so
lve p
rob
lem
s
Lead
er
Sta
nd
ard
Wo
rk
Gem
ba
Sta
nd
ard
Wo
rk
8 s
tep
s m
eto
do
log
y
Err
or
Pro
ofi
ng
Cell
Desig
n
Pro
cess 3
P
5S
Pu
ll S
yste
ms
Level
Sch
ed
uli
ng
(Heij
un
ka)
To
tal
Sco
re
Test
Sco
re (
max 4
8)
Self Assess./Test 2 2 2 2 2 1 3 3 3 1 1 2 2 3 29 44
Calibration 2 2 2 2 2 1 3 2 3 1 1 2 1 2 26
GOAL for 2017 2 3
Self Assess./Test 2 2 2 3 3 2 3 3 3 2 1 2 2 3 33 45
Calibration 2 3 2 3 3 2 3 3 2 2 1 3 2 2 33
GOAL for 2017 3
Self Assess./Test 2 2 3 3 2 2 2 3 2 2 3 3 1 1 31 43
Calibration 2 3 3 3 2 2 3 3 2 2 2 3 1 1 32
GOAL for 2017 2 2
Self Assess./Test 1 2 2 2 2 1 3 2 3 1 2 1 2 3 27 38
Calibration 2 2 3 2 2 2 3 2 2 1 2 1 2 2 28
GOAL for 2017 3 2
Self Assess./Test 2 2 2 2 2 1 2 3 3 2 3 3 3 3 33 45
Calibration 2 3 3 2 3 2 2 3 3 2 2 3 2 2 34
GOAL for 2017 3
Self Assess./Test 2 3 3 3 2 1 2 2 2 2 1 2 3 3 31 41
Calibration 2 3 3 3 2 1 2 2 2 2 1 2 2 2 29
GOAL for 2017 2 2
Self Assess./Test 2 2 3 2 2 1 3 3 3 2 1 3 3 3 33 46
Calibration 2 2 3 2 2 1 3 3 2 2 1 3 2 2 30
GOAL for 2017 2
Self Assess./Test 3 3 3 2 3 2 3 2 3 2 1 2 2 1 32 40
Calibration 3 3 3 2 3 2 3 2 3 2 1 2 2 1 32
GOAL for 2017 2 2
Self Assess./Test 2 2 2 2 2 2 2 2 3 2 3 3 3 3 33 45
Calibration 2 3 3 2 2 2 2 2 3 2 3 3 2 2 33
GOAL for 2017 3
Self Assess./Test 2 2 3 2 2 2 2 2 3 3 3 3 3 3 35 46
Calibration 3 2 3 3 3 2 2 2 3 3 3 3 3 2 37
GOAL for 2017 3
Self Assess./Test 2 2 2 1 2 1 3 3 2 2 2 2 2 3 29 42
Calibration 3 2 2 1 2 1 3 3 2 2 2 2 2 2 29
GOAL for 2017 2
Self Assess./Test 3 2 2 1 2 1 2 2 3 3 1 2 2 3 29 43
Calibration 3 2 2 2 2 1 2 2 3 2 1 2 2 2 28
GOAL for 2017 2
Self Assess./Test 2 2 2 2 2 1 3 3 3 3 3 3 2 3 34 47
Calibration 2 3 3 3 2 1 3 3 2 2 2 3 2 2 33
GOAL for 2017 2
Self Assess./Test 3 2 3 3 2 3 3 2 2 3 3 3 3 3 38 41
Calibration 3 2 3 3 2 3 3 2 2 3 3 3 3 3 38
GOAL for 2017 3
Self Assess./Test 2 3 3 2 2 2 3 3 3 3 3 3 2 1 35 46
Calibration 2 3 3 2 2 2 3 3 3 3 3 3 2 1 35
GOAL for 2017 2
Self Assess./Test 2 3 3 2 2 2 3 3 3 2 2 3 2 2 34 44
Calibration 2 3 3 2 2 2 3 3 3 3 2 3 2 2 35
GOAL for 2017 3
Self Assess./Test 2 2 3 3 2 2 3 3 3 2 1 3 3 3 35 46
Calibration 3 3 2 3 2 2 3 3 2 2 1 3 2 2 33
GOAL for 2017 2
Self Assess./Test 3 2 2 2 2 1 2 3 2 2 2 3 3 3 32 44
Calibration 3 2 3 2 2 1 2 3 2 2 2 3 2 2 31
GOAL for 2017 3 2
Self Assess./Test 2 3 2 2 2 1 3 3 2 1 1 3 3 3 31 43
Calibration 2 3 3 2 2 1 3 3 2 1 2 3 3 2 32
GOAL for 2017 2 2
Self Assess./Test 2 3 3 3 2 3 2 3 2 2 3 3 2 3 36 42
Calibration 2 3 3 3 2 3 2 3 2 2 3 3 2 2 35
GOAL for 2017 3
Self Assess./Test 2 3 3 3 2 1 3 3 3 3 3 3 3 3 38 47
Calibration 2 3 3 3 2 1 3 3 2 3 3 3 3 2 36
GOAL for 2017 2 3 5
Self Assess./Test 3 3 3 2 3 3 3 3 3 3 3 3 2 2 39 48
Calibration 3 3 3 2 3 3 3 3 3 3 3 3 2 2 39
GOAL for 2017 3
Self Assess./Test 2 3 2 3 2 2 2 2 3 2 3 3 3 3 35 44
Calibration 2 3 2 3 2 2 2 3 3 2 3 3 2 2 34
GOAL for 2017 3 3
Total: Self-Assessm.50 55 58 52 49 38 60 61 62 50 49 61 56 61
Total: Calibration 54 61 63 55 51 40 61 61 56 49 47 62 48 44
0 has no knowledge/skill
1 has some theoretical knowledge, can work according written process
2 experienced user, can work individually
3 expert, has a lot of experience, can teach others
x GOAL - to became an expert
Manager 22
Manager 23
Manager 24
Manager 20
Manager 21
Manager 17
Manager 16
Manager 1
Manager 2
Manager 4
Manager 5
Manager 3
Manager 6
Manager 7
Manager 9
Manager 10
Manager 11
Manager 19
Manager 18
CONTINUOUS IMPROVEMENTCULTURAL
ENABLERS
STRATEGY
Manager 12
Manager 13
Manager 14
Manager 15
Self-assessment/calibration Test
L&D – Skills Matrix
18 June, 2020© S A Partners
L&D – Self Led
18 June, 2020© S A Partners
Management’s role is to support &
Inspire, not to direct and dictate.
• Source: Cheryl Jekiel 2011
Creating a Coaching Organisation
18 June, 2020© S A Partners
FIVE KATA COACHING QUESTIONS
1. What is the target condition?
2. What is the actual condition right now?
3. What obstacles do you think are preventing you
from reaching the target condition and which one
are you addressing now?
4. What is your next step or experiment and what do
you expect to happen?
5. How quickly can we find out what we have learnt?
KATA Coaching
18 June, 2020© S A Partners
► Hilti Group – 70:20:10 Deployment Model
70:20:10 Training
9.
Innovation
18 June, 2020© S A Partners
► Future markets
► Customer Needs
► Technology
9. Innovation
www.nowandnext.com/PDF/trends_and_technology_timeline_2010.pdf
“Plan to Fail”
18 June, 2020© S A Partners
► Integrated Technology
► Smart Products
► Data Capture & Management
► Supply Chain Optimisation
► Digitisation & RPA
9. Innovation
18 June, 2020© S A Partners
“Success consists of going from failure to failure
without loss of enthusiasm”
Prime Minister Winston Churchill
9. Innovation
10.
Benchmarking
18 June, 2020© S A Partners
► Understand where you are
► Gap Analysis - Where you want to be
► Provides Focus for activities
► What you measure matters!
Benchmarking
18 June, 2020© S A Partners
► Company Visits
► Awards
► Networks – Lean Forum
► Supply Chains
► Formal Assessments
Benchmarking
18 June, 2020© S A Partners
► Enterprise Excellence Assessment
► 3-7 Days on site
► Enterprise-Wide
► Gap Analysis
Benchmarking
Upcoming Webinar:
Tuesday 7 July 2020: 12.00-1.00 BST
Creating a Roadmap for Enterprise Excellence
Towards
World Class
Manufacturing
1. Vision & Purpose
2. Strategy Deployment
3. Systems Approach
4. Employee Engagement & Culture
5. Continuous Improvement System
6. Customer Focus
7. Leader Standard Work
8. Learning & Development
9. Innovation & NPI
10. Benchmarking
www.sapartners.com
Call:
Email:www.sapartners.com
Name:
+44 (0)783-222-3453
Ailsa Carson