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Warwick Lean Agenda Aug Wk1 July 12 2010

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Workshop Agenda

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Warwick Lean Agenda Aug Wk1 July 12 2010

  1. 1. Agenda: Lean Workshop – Rapid Site Assessment, Value Stream Mapping Day 1 (8:00am – 5:00pm) Introduction to Leadership team Lean Leader module and System Kaizen Approach 1 hr Rapid Site Assessment – Questionnaire and observation of core process steps of key profit center. Summary assessment and share findings with company principal (Laura Green) Day 2 (8:00am – 5:00pm) Break for lunch 12 -1 – Maintenance Technicians - STD Work  Introduction of core teams to Exercise Lean Group  Installation and maintenance process overview  Code of conduct for workshop  Discussion of who is customer ( internal and external) requirements  Define project scope (which Service Value Stream)  Installation and maintenance standardize work  Define the current process with the core team  Establish standard work with flow chart and template that defines the major steps, key points (safety note, critical note and quality note), reason for the key point and photographic picture is possible.  Train participants in new standard  Test and validate wherever possible.  Evaluation workshops forms completed (continuous improvement for EL Group Day 3 (8:00am – 5:00pm) Break for lunch 12 -1  Define the new product / process introduction elements to track  Develop / Review project plan for introduction (Gantt Chart) See steps below o Step 1 Initiate Project o Process Design o Process Validation o Launch Readiness Review (Documentation, Training, Materials,Prepared by John F Petak www.exerciselean.com 864.363.0984
  2. 2. o Equipment) o Step 2  Analyze Gaps and Failures in the Current Process.  Brainstorm Solutions o Step 3 o Design New Process using VSM with and determine targets o o Step 4 Install New Process.  Layout Production Area using 5S from the Start  Establish Information and Material Flows using Visual Management Only (Launch Board/Job Status Board)  Train Staff on Work Flows  Conduct Rehearsals o Step 5  Run and Debug New Process  1. Daily Meetings  2. PDCA Action Plan  3. Institutionalize Processes o Step 5 Verification  Develop VSM for new process based on what is known  Define process flow through flow chart and spaghetti diagram  Define targets for Knowledge Management (knowledge collection)  Define how standard work will be formatted (Procedure / flow chart / etc)  Evaluation workshops forms completed (continuous improvement for EL Group)  Day 4 (8:00am – 5:00pm) Break for lunch 12 -1  Develop an action plan that covers task, sequence, priority, resource and time scale Gantt  Keep the timescales realistic (30 – 60 days)  Integrate value stream plan with identified actions from the matrix of KAIZEN Systems  Evaluation workshops forms completed (continuous improvement for EL Group)Prepared by John F Petak www.exerciselean.com 864.363.0984
  3. 3. Day 5 (8:00am – 5:00pm) Break for lunch 12 -1  Summarize the week  Complete business drivers on metrics  Finalize Plan Do Check Act worksheet  Complete A3 Report  Prepare workshop participants for management review  Management Review  Follow up with management team  Evaluation workshops forms completed (continuous improvement for EL Group  DeparturePrepared by John F Petak www.exerciselean.com 864.363.0984

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