From the Perspective of the Worker Making Things Run Better

Mike Taubitz

Introductions

• Name and organization • Why are you here and what do

you hope to gain from this session?

3

How much variability do you have in your life?

Thoughts on what “From the Perspective of the Worker”

means??

4

From the Perspective of the Worker

• Deming philosophy • Respect for people • No denial of real world issues • Challenges traditional education and thinking • “0” risk, “0” tolerance and quest for perfection • Does management really listen to input from

below? 5

How do workers learn about what is expected of them?

6

Corporate “Standard” • Law or regulation • ISO, ANSI or other external standard • Best practice • Policy • Specific procedure

– Operational – Quality – Safety

• Other 7

What happens if the “Standard” does not consider a real – world

variable?

8

How and What do we communicate to workers?

9

10 10

Lean & Standardized Work

• Lean is the identification and elimination of waste

• Standards are the foundation for improving things

• Improving the standard improves performance

11 11 11 11

Continual Improvement

Time

12 12

Standardized work removes barriers to communication

• “Standards” come from above; “Standardized work” comes from workers

• With TaBRA, workers identify and assess risk • “Standardized work” also comes from workers

• It is their means and method for training others • Helps eliminate differences in work methods and

forces consensus • Facilitates communication with workers for whom

English is second language

13 13

Visual Controls

14 14

Visual Controls

15 15

Visual Controls Usually don’t need a computer to be effective…

16 16

17 17

Visual Controls for Safety

18 18

We take visual controls for granted

19 19

20

21 21

Example Office Standard

22 22

23 23

24 24

Electric panel well marked

25 25

26 26

27

Why it took me 10 Years to “Get it” on Standard Work

27

There is no “standard” way to “standardize” something Must fit specific task Use PDCA thinking and make “Adjustments” as appropriate

28

Be Careful What You Ask For

28

29 29

“Malicious Compliance” is following orders to a “T”

without respecting judgment of workers…

30 30

On a blank piece of paper,

draw a pig

Exercise #1

31

Compare your drawings……

32 32

• Are all the pigs the same? • Were the work directions clear? • How was the training you were given to

draw your pig? • Do you think we could improve the

training and directions to get our result to be closer to the same?

• Did anyone come around to watch and help you with your drawing?

Standardized Work

33 33

This time let’s use a paper template and standard work document

Standardized Work

34

Pig 101 Standardized Work

35

Draw a PIG Instructions 1. Use the drawing template 2. Draw a letter “M” at the top left intersection. Bottom center of “M” touches the

intersection. 3. Draw the letter “W” at bottom left intersection. Top center of “W” touches the

intersection. 4. Draw the letter “W” at the bottom right intersection. Top center of “W” touches the

intersection. 5. Draw an arc from the letter “M” to the top right intersection. 6. Draw another arc from the top right intersection to the bottom right “W.” 7. Draw an arc between the two bottom “Ws.” 8. Draw the letter “O” in the center left box. 9. Draw an arc from the top letter “M” to the top center of the letter “O.” 10. Draw an arc from the bottom left letter “W” to the bottom center of the letter “O.” 11. Draw an arc for the eye half way between the top “M” and the letter “O.” 12. Draw an arc for the mouth. Half way between the “W” and circle. Must be a happy

pig!!! 13. Draw the cursive letter “e” near the top of arc on the right. 14. And finally… draw two dots in the middle circle for the pig’s nose.

35

36 36

War Production Board, Bureau of Training, Training Within Industry Service, 1944, Job Instruction: Sessions Outline and Reference Material (Washington D.C.: U.S. Government Printing Office), inside back cover.

37

Job Safety Analysis vs Risk Assessment from Perspective of Worker

Job Safety Analysis

• 11 overall steps – #7 Jam ups in

Machine

• Hazards: Energized Equipment and Residual Heat

RA - Worker • 18 steps for #7 alone

– 22 Task – Hazard pairs

• Stepping over conveyor could result in trip / fall: – Likely probability – Minor to serious

severity – Low to High risk

37

Experiential Learning Is Not New “There are three classes of people in the world. The first learn from their own experience. These are wise. The second learn from the experience of others. They are happy. The third neither learn from their own experience nor the experience of others. These are fools. “A man of the best parts and greatest learning, if he does not know the world by his own experience and observation, will be very absurd, and consequently very unwelcome in company. Lord Philip Dormer Stanhope Chesterfield (1694 – 1773), English Statesman and Man of Letters

38

39

40

41

42

43

44 44

Exercise

• Using PDCA and critical thinking, which is the best way to hang toilet paper? – Under or – Over?

• Take a few minutes and list “why” for your choice

44

45

Perhaps We Need to Rethink Basics

Dick Danjin, retired UAW Int’l Rep 45

46

Making Things Run Well

46

Deming’s 14 Points 1. Create constancy of purpose for

improving products and services 2. Adopt the new philosophy 3. Cease dependence on inspection to

achieve quality 4. End the practice of awarding business

on price alone; instead, minimize total cost by working with a single supplier

5. Improve constantly and forever every process for planning, production and service

6. Institute training on the job 7. Adopt and institute leadership

8. Drive out fear 9. Break down barriers between staff

areas 10. Eliminate slogans, exhortations and

targets for the workforce 11. Eliminate numerical quotas for the

workforce and numerical goals for management

12. Remove barriers that rob people of pride of workmanship, and eliminate the annual rating or merit system

13. Institute a vigorous program of education and self-improvement for everyone

14. Put everybody in the company to work accomplishing the transformation

47

48 48

It may be simple, but…….