Day / Month / Year WebKaizen(c) Copyright 2010 - Kate Cornell 1.

Day / Month / Year

WebKaizen(c) Copyright 2010 - Kate Cornell1

1. Kickoff & Housekeeping2. Analysis of Current State3. Select Areas of Focus 4. Causal Analysis5. Root Cause Analysis6. Create Possible Solutions 7. Prioritize and Select Solutions8. Solution Impact Metrics9. Assign Solution Owners10. Plan to Implement


Schedule1.5 hours – Kickoff/Current State/Focus Areas Break2 hours - Causal Analysis/Root Cause Analysis Lunch2.5 hours – Create & Select Solutions Break1.5 hours – Metrics/Assign Owners/Next Steps

Code of Conduct◦ Turn off email and IM◦ Stay on task and on time◦ All ideas are good ideas◦ Interactive session


Problem Statements◦Problem #1◦Problem #2◦Problem #3

Objectives◦#1◦#2◦#3


Team A Objective 1

Team B Objective 2

Team C Objective 3

List names here List names here List names here

Audio BridgeWeb Conference Info



ScribePresenter

ScribePresenter

ScribePresenter


“Just the facts ma’am, only the facts.”Sgt. Joe Friday, Dragnet


Describe current performance here Show gap between current state and

desired state


Insert graph of current state here


“Our thoughts create our reality – where we put our focus is the direction we tend to

go.”

~ Peter McWilliams



Review metrics and Process. Isolate areas with the greatest potential impact


1.

2.

3.

4.

Breakout groups review metrics & processReturn with 3 to 4 Areas of Focus

20 minutes

http://www.online-stopwatch.com/



Focused Affinity Matrix


The 6 Ms (used in manufacturing)

Machine (technology) Method (process/inspection) Material (raw, consumables etc.) Man Power (physical work)/Mind

Power (brain work) Money Milieu (External Environment or

surroundings)

Miscellaneous Environment Measurement (Inspection) Maintenance Tools or applications Management

The 8 Ps (used in service industry)

Product=Service Price Place Promotion People Process Physical Evidence Productivity & Quality

The 4 Ss (used in service industry)

Surroundings Suppliers Systems Skills

WebKaizen15

Areas of Focus Affinities

Ordering at the Wholesaler

Delivery from the Wholesaler

Unpacking the truck

Refrigeration On-Site

ProductIndirect Product Not careful

enough

Place Distance is too great

Distance to fridge from

truck

Not enough room between

shelves

People Delivery takes too long

Need training in handling

Process We are last on their route

Tools Ordering takes too long

Refrigeration not cool enoughBox handles too

flimsy

Need better dollies

Man-Power Not enough people


Objective – Associate applicable causal factors with Areas of Focus

Match causes by Affinity with Areas of Focus. This will filter out causal factors not important in correcting our problem.

Fill in the Focused Affinity Matrix.

30 minuteshttp://www.online-stopwatch.com/



Some causal factors are already at a root cause level.

The number 5 is not an absolute, ask why until you are at root cause.

It is impossible to get to an absolute root cause, therefore, root cause is subjective.

Consider root cause being the lowest level of causation that is within your control.


Ordering at the Wholesaler

Delivery from the Wholesaler

Unpacking the truck

Refrigeration On-Site


Fill in the Root Cause Analysis Sheet45 minutes




“I think the next best thing to solving a problem is finding some humor in it.”

~Frank A. Clark


Visualize the perfect solution Don’t be bound by what is done today. Don’t be discouraged by prior failures. Do it a different way One or Two Words – no sentences There is no Wrong Idea in Brainstorming Correct response = “Good Idea” We’ll sort for the best solutions later Put an identifying number next to each

solution


Areas of FocusOrdering at the

WholesalerDelivery from the

WholesalerUnpacking the truck Refrigeration On-Site

1. XXXXX3. XXXXX

5. XXXXX 2. XXXX6. XXXX

4. XXXX


Populate List of Solutions

30 minuteshttp://www.online-stopwatch.com/



Cascading Impact Analysis


Restate Objective Cascading Impact Analysis Determine top three constraints List Primary Constraint at bottom of

Impact/Constraint Diagram List Secondary and Tertiary Constraints at

bottom of Dual Constraint Diagram Perform the Cascading Impact Analysis Use identifying numbers – No words


IMPACT / CONSTRAINT DIAGRAM

10

9

8

7

6

5

4

3

2

10

18

17

1614

15

13

12

11

1

WebKaizen(c) Copyright 2010 - Kate Cornell 28

If there are more than 3 solutions in the upper right hand quadrant….

Use the Cascading Impact Analysis method by populating the Dual Constraint Diagram


DUAL CONSTRAINT DIAGRAM

10

9

5

4

1817

16

1412

WebKaizen(c) Copyright 2010 - Kate Cornell 30

1.

2.

3.

4.


Use Cascading Impact AnalysisList Prioritized Solutions

45 Minutes




“Statistics are no substitute for judgment”

~ Henry Clay


Identify the potential change that each solution can have on the problem

Example:1. Figure the universe of opportunities available

for each solution.2. Assess the Impact against the universe of

opportunities.3. List the value and the % of the result.



Starting Measures of Unspoiled Produce 630 78%

Solution 18 70 9%

Solution 22 15 2%

Solution 11 10 1%

Solution 12 10 1%

Total Objective Starting at the end of next month, the raw produce spoilage levels will be less than 10%.

735 92%

45 minutes




Plan the Work – Work the PlanJoint Team Effort


Solution Owner & Resources


Owners determine date of team meetings Activities and action items assigned Work Planned Work Executed Capture Results in Metrics


Worksheets

Process Map

• Copy your process map here

WebKaizen (c) Copyright 2010 - Kate Cornell

Areas of Focus


1.

2.

3.

4.

Affinities• The 6 Ms (used in manufacturing)• Machine (technology)• Method (process/inspection)• Material (raw, consumables etc.)• Man Power (physical work)/Mind

Power (brain work)• Money• Milieu (External Environment or

surroundings)

• Miscellaneous• Environment• Measurement (Inspection)• Maintenance• Tools or applications• Management

• The 8 Ps (used in service industry)• Product=Service• Price• Place• Promotion• People• Process• Physical Evidence• Productivity & Quality

• The 4 Ss (used in service industry)• Surroundings• Suppliers• Systems• Skills


Focused Affinity Matrix WorksheetAreas of Focus Affinities


List of Root Causes WorksheetAREAS OF FOCUS


List of Solutions Worksheet


AREAS OF FOCUS

Impact / Constraint Matrix Worksheet


Dual Constraint Worksheet


Top Solutions Worksheet1.

2.

3.

4.

5.


Solution Impacts WorksheetStarting Measures # %

Solution 1 -

Solution 2 -

Solution 3 -

Solution 4 -

Solution 5 -

Total Objective


Solutions & Owners Worksheet

Solutions for Problem #____ Owner & Resources

Solution #1

Solution #2

Solution #3

Solution #4

Solution #5


Day / Month / Year WebKaizen(c) Copyright 2010 - Kate Cornell 1.

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