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Focused Improvement

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Michelle Johnson

on 29 April 2014

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Transcript of Focused Improvement

Situational Problem Solving
Systemic Problem Solving
MillerCoors FI-Problem Solving Process
5 Why & Fishbone Analysis
Focused Improvement
What is FI?
Focused improvement is the best practice of:
- ensuring improvement in key performance areas by focusing on major wastes, variability, and other problem areas

- Establishing problem-solving structures and skills throughout the organization.
Dual Approach
Sporadic vs. Chronic Problems
Unless you take action on the root cause…the problem will reoccur!

Structured problem solving aims to identify the root cause of the problem and thus enables you to get rid of it for good.
1st step is gathering the team

Should include:
People involved in the incident
Others not directly involved
Facilitator:
keep the team focused & ensure the analysis is conducted correctly
Multi-disciplinary group:
can provide outside views
see things overlooked by those close to the area
5 Why Preparation
Fishbone
Analysis
Fishbone identifies many possible causes for a problem
It structures brainstorming into 6 categories (5M’s &1E):
Machine
Method
Measurement
Material
Manpower
Environment
Conducting the fishbone analysis…
Allocate possible root causes to relevant category
Add sub-branches if required
Causes may appear in more than one category
Identify those with high possibilities
Multi-voting
structured problem solving
Place an in the ones that are a YES.
How Effective Is Our Current Problem Solving?
Do you find that you fix the same chronic problem over and over again?
Do you find that the same problem occurs in various areas in the brewery?
Do you spend most of your time fighting fires, rather than preventing problems and improving things?
Do you often hear the comment: There is never enough time or money to eliminate a problem permanently, but enough to fix it again and again?
Do you spend a lot of time chasing wrong solutions?
Do you rely heavily on the experience of a few key specialists to diagnose or fix a problem individually?
Is your operation often interrupted by unexpected stoppages?
Do you sometimes wish you could remember how a specific problem was solved previously?
Do you feel like you are dealing with symptoms of problems, rather than with causes?
Do people spend a lot of time blaming others for problems?
Are people frustrated by the lack of progress?
Are most problems referred to management or support functions (like maintenance) to be resolved?
Do we waste a great deal of time and material in brewing because of problems and issues?
Do we have customer complaints?
Is it common in brewing that anything that can go wrong does?
How Effective Is Our Current Problem Solving?
1. Do you find that you fix the same chronic problem over and over again?

2. Do you find that the same problem occurs in various areas in the brewery?

3. Do you spend most of your time fighting fires, rather than improving things?

4. Do you find there is never enough time or money to eliminate a problem permanently, but enough to fix it again and again?

5. Is your operation often interrupted by unexpected stoppages?

6. Do you sometimes wish you could remember how a specific problem was solved previously?

7. Do people spend a lot of time blaming others for problems?

8. Are people frustrated by the lack of progress?

9. Are most problems referred to management or support functions (like maintenance) to be resolved?

10. Do we have distributor complaints?
* Focused Improvement Best Practice

* Types of Problems

* Structured Problem Solving Tools

* Standardizing Improvements

* Loss and Waste Analysis
Agenda
Improves SPQSCS
Offers greater job satisfaction
Offers greater sense of involvement and ownership
Develops problem-solving skills
Develops a better understanding of key losses and how they impact the business
Enhances teamwork
Ensures sustainable solutions by eliminating root causes
Benefits of FI
Stage 1 : Fire Fighting
No consistent definitions and measurement systems for losses and wastes are in place. No analysis of problem areas or structured problem solving.
Stage 2 : Loss Awareness
Losses and wastes are defined and quantified for process areas and effective measurement systems have been implemented accordingly. Daily problem solving and improvement projects focus on mitigation of major losses and wastes.
Stage 3 : Systematic Improvement
There is a clear focus on driving down losses and waste at plant level. Problem solving techniques have been deployed to all plant resources and levels.
Stage 4 : Pro Active Improvement
Focus is on variability reduction, prevention and all forms of non-value-adding activities throughout the Supply Chain.
Stage 5 : Value Chain Optimization
The entire Value Chain is considered as an integrated unit and losses and waste are optimized for its impact on the whole.
Role of FI
Advantages of Team Problem Solving
What does a Winning Focused Improvement Culture look like?
What are some Culture Killers?
What is a Problem?
Types of Problems
Problem Solving Toolbox
add example
Writing a Problem Statement
5 Why
Loss and Waste Analysis
Considering the Implications
5 Why Tip:
5 Why Tip:
It's critical to verify the identified root cause is the actual root cause
Try to reproduce the problem!
If the problem can't be reproduced, there's a good chance the actual root cause was not identified - Revisit the 5 Why!

If the problem can be reproduced, CONGRATULATIONS! You can now eliminate it and see the improvement in your metric.
Common Mistakes
One person filling out the form alone
This will limit the information used to get to the true root cause
Deviating from cause and effect
This will lead the team down the wrong road
Solutions in disguise
Watch for things like “We need more space” vs. “The work area is congested”.
Blaming people as the root cause
This is the fastest way to kill the 5Why program. The team needs to focus on What happened, not Who’s to blame
Focusing only on why the defect or issue wasn’t caught or contained, not why it occurred
If the root cause isn’t eliminated, it’s only a matter of time until the problem will be back.
Eliminating Waste is the
Key to World Class!
What do our consumers want to pay for when they buy a 6-pack?
7 Major Wastes
Overproduction
Waiting
Transporting
Overprocessing
Unnecessary Inventory
Unnecessary Motion
Defects
Group Exercise: Provide examples for each
Toast Video
Standardizing Improvements
SOP’s
One Point Lessons (OPL)
Troubleshooting Diagrams
Mistake Proofing – Poka Yoke
Poke Yoke - Mistake Proofing
Examples
Summary
From memory, answer the following questions as a team.

1. What are the names of the streets on the sign at the intersection?

2. What was the young man doing to the parked car?

3. What is the name of the produce store?

4. What was the man sitting at the table taking?

5. What were the men running across the street carrying?

6. What was the price for the grapes?

7. What is the name of the café?

8. What did the woman drop from the upstairs window?

9. What is on “special” at the produce store?

10.What was the man stealing from the produce market?
http://goanimate.com/videos/0NEXElgdPmmY?utm_source=emailshare&refuser=0mPO-tomXUfs
http://goanimate.com/videos/0Ir_DHc_0qwo/1
Exercises
What common mistake did this team make?
What common mistake did this team make?
What common mistake did this team make?
5 Why
Case Study
Exercise
Fishbone
Exercise
You will be shown a picture of a crime scene

You have 20 seconds to memorize as much of the picture as possible

After time is up, we’ll answer 10 questions together as a team
How many did the team answer correctly?

How many would you have answered correctly on your own?

The same is true with RCA’s
To be successful, the analysis needs to be completed by a team
One person will not have all the information
Everyone sees things differently
Create a list of
sporadic/situational and
chronic/systemic
problems
http://www.pgconnectdevelop.com/
Situational Problems
Systemic Problems
We could:
Add a bucket
send the water to a drain
replace the valve

These only correct the problem temporarily, but it does not address the root cause! We need to ask why we had to perform these tasks.
Don't forget: Conduct the 5W&1H first!
Customer Service Loss and Waste Analysis

http://www.ir.mbc.com/wcm%20home/Projects/Shared%20Documents/Loss%20and%20Waste%20Trees/Loss%20and%20Waste%20-%20CS.xlsx
Brewing Loss and Waste Analysis

http://www.ir.mbc.com/wcm%20home/Projects/Shared%20Documents/Loss%20and%20Waste%20Trees/Loss%20and%20Waste%20analysis%20-%20Brewing%202013.xlsx
http://www.ir.mbc.com/wcm%20home/Projects/Shared%20Documents/WIP%20Loss%20FI%20-%202.ppt
Full transcript