Lean training I created in 2009. I am providing this training for Manufacturing Alliance, a local association in Minnesota.

7. What are the origins of PD?

10. 1994: Henry Mintzberg “ Strategy cannot be planned because planning is about analysis and strategy is about synthesis.” He adds: “Strategies are created by emphasizing informal learning and personal vision.” Mintzberg, 1994

12. Strategy = Analysis + Intuition “ Chess is not all calculation. I do the calculation, but I also look at my opponent, his body language, and his intuition.” Alexander Kotov, 1971

15. Review of PDCA REFLECT GRASP THE SITUATION HYPOTHESIS EXPERIMENT ADJUST Plan Do Check Act

16. Comparing Broccoli and PDCA? … Fractals

17. Fractals View of PDCA Business Planning Activity Planning Problem Solving / Kaizen Daily Work Std Work - CI A3 Project A3 Plan Policy Deployment Tools Activities Activities Tools A3 Strategy

19. Activity 1 – Grasping the Situation The Advisory Committee Phase 1: Read page 1 & 2 and discuss by group (7 min) Phase 2: Read page 3 and discuss by group (5 min) Phase 3: Class reflection (8 min)

22. A3 Strategy Construction

23. A3 Strategy Template

24. The Road Metaphor Current Condition (Where we are) Our Vision (Destination) Use Policy Deployment Use Operational Plan Avoid Distractions!

27. Reflect on Current Conditions

28. Activity 2 – Dashboard Analysis Display Plus Plasma Case Study Phase 1: Study the graphs to decipher the story (5 min) Phase 2: Compare notes and discuss by group (5 min) Phase 3: Class reflection (5 min)

30. Develop Image of Desired Future

34. Activity 3 – Reflect and Plan Display Plasma Plus Phase 1: Read case study and assign roles (5 min) Phase 2: Catch ball / Tree Analysis (7 min) Phase 3: Class Reflection (5 min)

35. Prioritize Needs - Objectives

38. Affinity Diagram Step 1 - Generate ideas (Brainstorm) Step 2 - Display ideas Step 3 - Sort ideas into groups Step 4 - Create header cards Step 5 - Draw finished diagram.

39. Affinity Diagram Group ideas by short, action title Objectives Header 1 Header 2 Header 3 Header 4 Header 5 Header 6 Activity Activity Activity Activity Activity Activity

40. Create One-Page Plan

43. Contingency Plan

46. Deploy the plan Plant Management Deployment Leader Cost Deployment Leader Delivery Deployment Leader Quality Deployment Leader Safety Supply Chain VSM 3 VSM 2 VSM 1 Cost Delivery Quality Safety Functional Leader

48. Deploy the Plan Deployment Leaders Mgr & Supervisors PLAN Plant A3 Strategy High-level SQDC Cost A3 Strategy Delivery A3 Strategy Quality A3 Strategy Safety A3 Strategy A3 Strategy A3 Strategy A3 Strategy A3 Strategy ids Plans & Projects P D A C

51. Example of “Go See Quality”

53. Micro Check and Adjust Bowling Chart Dashboard

55. Connected Check Micro Check and Adjust Team Supervisors, Team Leads Monday Plant/Deployment Leaders Plant Mgr, Deployment Ldrs, VS Mgrs Wednesday Value Stream VS Mgrs, Supervisors Tuesday

57. Mid/End Year Check and Adjust

58. Deployment Leaders & Mgrs Deployment Leaders Mgr & Supervisors Mgr & Supervisors CHECK PLAN DO ACT (corrective actions against Plans) Mid/End Year Check and Adjust Plant A3 Strategy High-level SQDC Cost A3 Strategy Delivery A3 Strategy Quality A3 Strategy Safety A3 Strategy A3 Strategy A3 Strategy A3 Strategy A3 Strategy ids Plans & Projects A3 Reflection A3 Reflection A3 Reflection A3 Reflection Quarterly & Year-End Cost A3 Reflection Delivery A3 Reflection Quality A3 Reflection A3 Reflection Safety P D A C

59. Annual PDCA Cycle

60. Putting Everything Together

61. Putting Everything Together