Kaizen Leader Training: Improving the Practice-to

Transcription

Kaizen Leader Training:
Improving the Practice-to-Performance Ratio
Sponsored by:
Whitney Mantonya
Collaborative Lean Solutions
Ellen Milnes
MoreSteam.com
MoreSteam.com
• Process Improvement Training &
Technology
Select Customers:
• Trained 500,000+ Lean Six Sigma
professionals
• Served over 50% of the Fortune 500
• Courses reviewed and approved by
ASQ and PMI
• Academic Partnerships with The
Ohio State University, University of
Notre Dame, California Polytechnic
University, and George Washington
University
3
© MoreSteam.com 2016
4
63:1
The ratio of practice to play
5
Data was collected from two sources.
Answers to the first two survey questions (training
drivers and most important skills) were collected during
a series of one day benchmarking conferences conducted
in the US and Europe during 2014 and 2015.
Answers to questions about eLearning effectiveness
were collected from MoreSteam’s larger enterprise
customers in a survey conducted in September of 2015.
Respondents include IBM, HP, Hertz, AB-InBev, Tyco,
Honeywell, PPG, Eli Lilly, Ohio State, Emerson Network
Power, Nationwide Insurance, and Cardinal Health.
6
What skills/tools are most important to you and
your people?
Skill at Implementing Change
64
Lean Methods
35
Simple Data Analysis Tools
32
Team Leadership
Complex Data Analysis Tools
22
8
Data collected over last 12 months
7
Which driver has the most influence on your
training design?
Training Effectiveness
33
Training Flexibility
13
Travel Cost
12
Instructor Time/Cost
Something Else
11
3
Data collected over last 12 months
8
How effective is your blended training model compared
to the training model you used previously?
30% Better
Median
Mean
39.5% Better
0%
25%
Std. Deviation
50%
35.7%
N = 29
9
Some things don’t need much design
work…
10
Some do…
11
12
Learning Activities Used in Blended Model
– Beyond eLearning
Project Work
One-on-one Coaching
Study Halls
Online Sims (SigmaBrew, InBox)
Physical Sims (catapult, Sigma Station)
Classroom Lecture
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0% 100.0%
All responses: n=29
13
Learning Activities Used in Blended Model
Project Work
One-on-one Coaching
Study Halls
Highest Improvement
Lowest Improvement
Online Sims (SigmaBrew, InBox)
Physical Sims (catapult, Sigma Station)
Classroom Lecture
0.0%
20.0%
40.0%
60.0%
80.0%
100.0%
Comparison of 9 Worst vs. 8 Best
14
What are the most important success factors for your training model?
Success Factors
Structured timeline and deadlines
Realistic Simulation/Practice
Scheduled Weekly/Monthly meetings
Reporting
Leadership Support for Training Time
0
1
2
3
4
From responses with greatest improvement
15
If you had a do-over on your blended learning design,
what would you do differently?
Do-Over
More Simulation
Realign Content - Quick Improvement
Communicate Real Success Stories, Case
Study
In-Person Study Hall, Workshop
More Practice, Shorter Cycles of
Application
Presentation Version of Content
0
1
2
3
4
5
6
7
8
From responses with least improvement
16
Bloom’s Taxonomy
Create
Evaluate
Analyze
Apply
Understand
Remember
Bloom's Taxonomy (Revised)
17
Learning Activities
Active
Bloom’s Taxonomy
Dynamic
Complex
Open-Ended
Creating
Evaluating
Analyzing
Applying
Passive
Structured
Simple, Linear
Close-ended
Understanding
Remembering
18
Open-Ended
Map Your
Learning Activities
Close-Ended
Simple
Complex
19
Open-Ended
Card
Drop
Lean
Process
Sim
(InBox)
Project
Work
SigmaBrew
DMAIC
Case
Study
Dice
Catapult
Drag
& Drop
Close-Ended
Quiz
Simple
Story Problem
Quiz with Data
Complex
20
Key Ingredients:
Realistic Simulation
More Components
Key Methods:
Clear Expectations,
Structure, Follow-up,
Leadership Support
21
Example: Kaizen Leader Training
What Is Kaizen?
Continuous Improvement Continuum
Measure
Analyze
Improve
Control
VARIATION
Define
Kaizen
event
WASTE
GB/BB
Project
Quick
Hit
Small Improvements to
Individual Daily Work
Rapid Implementation of
Simple, Visible Solutions
Problem Solving Leveraging
Data Analysis
Kaizen:
the Rugby of Process Improvement
Guiding Principles of
Kaizen Training Design
• Participants need to know more than
just lean tools
• Use InBox simulation as a Kaizen event
• Provide multiple opportunities to
practice facilitating the common Kaizen
activities
STEP 1: BUILDING THE KAIZEN
MODEL
Kaizen Activities
Pre-event Prep (
8-12 hrs)
Event Week- 5 days
Follow up actions- 15 days
Kaizen Event Flow – 4 ½ days
Day 1
D/M
Day 2
A
Day 3
I
Day 4
•Team Training
•Charter/SIPOC Review
•VSM/Process Mapping
•NVA/Pain Point Identification
•Root Cause Analysis
•Brainstorm and Select Solutions
•Future State Mapping
•Kaizen Week Action Plan
•Midweek pitchout preparation and presentation
•Pilot and/or Implementation of Solutions
•Implementation of Solutions
I
Day 5
C
•30 day action plan
•Final Financial Calculations
•Final Pitchout Preparation and Presentation
Certification Requirements
Training
Observation
• Completion of on-line and classroom
training curriculum
• Participate/observe a minimum of 1
kaizen event
• Lead 2 events
Event Lead
Considerations
• Timing of participation
– Prior to training
– Sponsored event week
• Coaching support
– Experienced resources to support
– Leverage short term external support to build
capability
STEP 2: BUILDING A BLENDED
PROGRAM
Training Goals
Tool
Knowledge
• Commonly used lean
tools
• What they tell you
• When they are used
Kaizen
Execution
• Flow of the Kaizen
event
• Picking the right tools
for the problem at
hand
• Sequence of activities
Facilitation
• Build confidence in
facilitation skills
• Provide multiple
opportunities to
facilitate and observe
others in the facilitation
of specific tools
Training Design
On-line
Curriculum
• Kaizen Model
• Project Definition
• Metrics
• Lean Tools
(22 hrs)
Classroom
Session
(2 days)
• Brief tool review with practice
exercises
• Leverage simulation as a proxy for
actual Kaizen event
• Provide multiple opportunities to
practice facilitation
Classroom Sessions: Keeping it
Interactive
Tennis Ball: Setting the Stage
Image courtesy of http://wardrounds.northwestern.edu
Shapes: Build understanding of the
impact of lean tools
Standard Pig: Demonstrating Impact of
Standard Work
Round 1
• Using the grid provided draw a side profile of a pig, centered
on the page
• Make sure the pig’s head is facing left
• Pig must be large enough so that a piece of it is in every box
EXCEPT the top right
• You have 2 minutes to draw your pig- we will post each one
on the wall
Round 2:
• Use distributed work instructions to draw a pig on the grid
on the wall
Round 3:
• Use newly distributed work instructions to draw a pig on the
grid
on the wall
InBox: Experience Facilitating
a Kaizen Event
Piloting the Program
Pilot Lessons Learned
• Blended training model effective and efficient way to
train kaizen leaders
• Classroom session should be interactive and provide
participants with multiple opportunities to practice
facilitation
• Demand for training should be balanced with ability
to provide coaching support and opportunities to
observe or co-lead prior to independently leading
kaizen events.

Kaizen Leader Training: Improving the Practice-to

Transcription

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