YELLOW BELT TRAINING (LEAN DAILY) SIMPLER. FASTER. BETTER. LESS - - PDF document

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YELLOW BELT TRAINING (LEAN DAILY) SIMPLER. FASTER. BETTER. LESS - - PDF document

YELLOW BELT TRAINING (LEAN DAILY) SIMPLER. FASTER. BETTER. LESS COSTLY. lean.ohio.gov Objectives Start thinking Lean Introduce Lean concepts that can be used for daily improvements Basic knowledge on Lean tools for


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YELLOW BELT TRAINING (LEAN DAILY)

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

lean.ohio.gov

Objectives

  • Start “thinking Lean”
  • Introduce Lean concepts that can be

used for daily improvements

  • Basic knowledge on Lean tools for

removing waste and improving customer value

  • Demonstrate the concepts applied for

improvement in Government processes

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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WHAT IS LEANOHIO?

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What is LeanOhio?

  • Office within DAS
  • Staff of 3
  • Facilitated more than 80 process

improvement events

On average, process time and process steps reduced by more than 50%

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

lean.ohio.gov

LeanOhio Mission

“Make state government in Ohio simpler, faster, better, and less costly.”

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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CORE PROCESSES

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Kaizen Events

  • Introductions
  • Scope
  • Walk Through
  • Current State

Day 1

  • Training
  • Brainstorming
  • Analysis

Day 2

  • Clean Sheet

Redesigns

  • Future State

Day 3

  • Commitment
  • Implementation

Day 4

  • Results
  • Report out
  • Celebration

Day 5

Intensity

  • Compressed

Time

  • Efficient
  • Keeps

Momentum Immediacy

  • That week
  • Resources

Available

  • Leadership

Support Importance

  • High profile
  • Waste

Ridden

  • Customer

Impact

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Kaizen Events

  • Improve significantly

– Time and steps

  • Out of Scope

– No additional $ – No additional people – Can’t change laws – Can’t throw IT at the problem – No one loses their job

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Consultation

Strategic Planning Value Steam Mapping Process Improvement Results Management ALIGN PRIORITIZE TRANSFORM SUSTAIN

Assist with development

  • f mission, vision, values

SWOT Analysis Prioritize critical issues Identify core processes Develop goals and

  • bjectives

Ensure alignment Evaluate current state Envision future state Identify opportunities relating to workplace culture Determine and prioritize improvement projects Conduct and guild “voice of the customer” activities to gather data Analyze, compile data for use in events Scope, coordinate, and facilitate Kaizen events Apply DMAIC to core processes Set up Systems to ensure bottom‐up improvements Facilitate 5S process to transform work area layout Facilitate 3P (production preparation process) to design new processes Assist with development

  • f:
  • Meaningful Metrics
  • Scorecards
  • Dashboards

Provide training and guidance

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Training and Development

White Belt

  • 3 hour Lean awareness training

Yellow Belt

  • 1 day Lean daily overview

Camo Belt

  • 4 days + demonstration of learning
  • Lean tools for government

Green Belt

  • TBD

Black Belt

  • TBD
  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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LeanOhio Network

  • Over 1000 members

– 44 State agencies

  • Agency Circles

– Single LeanOhio Contact

  • Public Safety
  • Health and Human Services
  • Business and Industry
  • Infrastructure and

Environment

  • Admin and Financial
  • Boards and Commissions
  • Hands‐on learning

– Side‐by‐side knowledge transfer – Co‐facilitating events – Challenges facing

  • ther agencies

– Strategic planning – Capstone project

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Lean.Ohio.gov

– Training Materials – Results – LeanOhio Network – Lean Tools and Guides

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WHAT IS LEAN?

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What is Lean?

  • A time‐tested method and set of tools to help

us improve “how” we produce our products and services. Lean focuses on speed without sacrificing quality for the customer

What does Lean look like at home?

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What is Lean?

  • Lean helps us understand:

– What adds value to our customers – How work gets done – How we can identify root causes of problems – What an “ideal/no waste” process looks like – How we can improve performance – Whether process changes were successful

Lean is also a mindset, where we ask each day “How can we make our services better for customers?”

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Simplify Your Work

  • Eliminate tasks that do not add

value

  • Make things easy and intuitive

for customers and staff

  • Standardize repetitive tasks
  • Leverage systems / staff talent
  • Streamline process before

automation!

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LeanOhio White Paper

  • No IT solutions until you

improve the process first

  • Sequencing the process

improvement ahead of technology is critically important to maximizing the gains that automation may offer

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How Do We Define Value‐added?

  • Customer is willing

to pay for it

  • Actually transforms

a product or service

  • Done correctly the

first time

  • Consumes resources

without creating value for the customer (often CYA)

  • Low percent of the

time work is complete and accurate

  • Requires extra time,

effort, or resources

Value‐added

  • vs. Non Value‐added
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Examples

  • Receiving a payment,

permit, certificate, etc.

  • Educational training
  • Receiving data/info

for making decisions

  • Receiving medical

services

  • Counseling on mental

health issues

  • Double/triple

checking

  • Multiple signatures
  • Re‐entering

information into a system

  • Rework
  • Waiting

Value‐added

  • vs. Non Value‐added
  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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TIM U WOOD

Transportation Unnecessary movement of products & materials Information/Inventory Unnecessary storage of products & materials Motion Unnecessary movement by people (e.g., walking) Underutilization Underutilizing systems and people’s skills & knowledge Waiting Wasted time waiting for the next step in the process Overproduction Production that is more than needed or before it is needed Over Processing More work or higher quality than is required by the customer Defects Efforts caused by rework, fixing mistakes, and incorrect information

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KEY PRINCIPLES OF LEAN

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Seven Key Principles of Lean

1. Define value in the eyes of the customer 2. Identify the process for a service or product 3. Create continuous flow without interruptions 4. Reduce defects in services or products 5. Let customer pull what they want 6. Pursue perfection (Six Sigma ‐ 3.4 DPMO – 99.99966%) 7. Eliminate or reduce variation

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Voice of the Customer

Key Principle #1: Define value in the eyes of the customer

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Why Use VOC?

“We find ourselves wondering what our customers are thinking. Are we meeting their needs and expectations? Are they happy with

  • ur work?”
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Government VOC

  • Who is the customer???

– Businesses that provide various products/services to government – Drivers on highways – Motor vehicle owners getting licenses and registration documentation – Students and parents in education – Medicare, social security, other social service recipients – Etc.

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Voice of the Customer

  • Focus groups
  • Surveys
  • Comments and complaints
  • Ultimately determine what the

customer cares about

  • This helps guide what to focus on
  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Focus Groups

  • A group brought together

to discuss a particular topic or issue

  • Should be conducted

before a project begins and after a project ends

– Establish a baseline – Look for improvements

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Continuous Flow

  • Key Principle #3:

Create continuous flow without interruptions

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Batching

  • Bunching items together and processing them
  • “Enemy of speed”
  • Batching can sometimes be more efficient for

individuals, but slows down the processes as a whole.

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Batching

“Let’s wait until we get a bunch” “Let’s process them as they come in”

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FISH (First‐In‐Still‐Here)

  • Work started on all requests immediately (to

be able to say to taxpayer that “yes, we’re working on it”)

  • Highly variable process lead time, lots of fire

fighting

  • Search and move process

– Somebody yells, find request, expedite until somebody else yells, etc.)

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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FIFO (First‐In‐First‐Out)

  • Work is streamed into the process
  • It flows through uninterrupted
  • Few handoffs, delays and approvals
  • Faster and less waste
  • Taxpayer gets what they want, when they

want it

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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LEAN IN GOVERNMENT

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Department of Taxation

Tax Appeals Kaizen Event

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Simpler: 143 steps to 96 steps and 4 entry points to 1 entry point Faster: 18 – 32 months to as few as 7 – 20 days Better: This streamlined process steers cases to the right work unit right away. Simple cases are fast‐ tracked while complex cases go to legal staff. Less Costly: Projected savings of $63,000 from reduced mail processing time, certified mail, and related expenses.

Savings

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Attorney General

Bureau of Criminal Investigation (BCI) Kaizen Event

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Simpler: 187 steps to 84 steps Faster: Average of 125 days to an Average of 20 days Better: Police departments and county sheriffs will receive DNA results quicker Less Costly: Projected $57,000 in paper savings annually

Savings

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Lean in Government

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LEAN DAILY ‐ HUDDLES

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Do You Huddle?

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What is a Huddle?

  • A short daily meeting focused on the business

to:

– See the status of work in real time – Make decisions about managing the work to meet goals – Support rapid, continual, incremental improvements – Communicate and learn – Yesterday, today and tomorrow

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“We huddle daily, because we can’t solve what happened last week.”

– Darrell Damron, Deputy Director of Lean Transformation Services, State of Washington

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Do Do Not

  • Start on time and

keep them short, very focused

  • Stand up
  • Meet around a

planning board (visual management)

  • Discuss non‐work

related items (i.e. tv shows, sports, etc.)

  • Bring distractions
  • “Over” talk projects

Huddles

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Discussion Topics

  • The status of our work today – are we meeting
  • ur goals and targets?
  • What can we do to get back on track today?
  • New ideas we can try to quickly improve –

fixing what bugs us

  • What do we need to communicate?
  • Obstacles we face today and how we can
  • vercome them?
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Sample Agenda

  • Individuals set goals for the week (Monday)
  • Report progress to goals (Tuesday – Friday), track

visually

  • Track and display key measures
  • Identify ways to get back on or stay on target
  • Review and assign improvement ideas (once a

week)

  • Share roadblocks, offer assistance, ideas and

insights

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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You’re doing it right if you see…

  • More problem solving
  • Less complaining
  • Better communication and coordination
  • Employee ownership and initiative
  • Improved morale
  • Self‐managing teams
  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Visual Management

  • Make the work visible
  • Determine what needs to be tracked on visual

boards for huddle discussions

  • See in real time the status of the work
  • Continue to improve – no one right way to do

this

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Why Use Visual Management

“My co‐workers and I don’t really know whether

  • ur work is having a positive impact. We can’t

tell for sure whether it’s meeting customer expectations, helping the agency achieve larger goals, or contributing in some other way.”

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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ODOT

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Customer Service Center Uses monitors for tracking:

  • 1. Employee ‘status’ –

available, not available

  • 2. Current customers in queue
  • 3. Longest current ‘hold’ time

Ohio Shared Services

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Accountability

  • Daily huddles are key part of Lean Daily
  • Team group meetings focusing on project

status and identification of challenges

  • Enables team to raise and address issues as

they occur, preventing larger problems from developing

  • Huddles typically occur in the same area, at

the same time each day

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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LEAN DAILY – PERSONAL KANBAN

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What is a Kanban?

  • Kanban is Japanese for “visual signal” or

“card”

  • In simplest terms it means better

communication through visual management

  • Commonly used as an indicator for re‐ordering
  • f stock (i.e. paper, gloves, equipment, etc)
  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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What is a Kanban?

  • Modeled after how

supermarkets restock shelves

  • Limits work‐in‐progress

and creates a pull system

  • Drives value for customers by having the

right items available, and creates flow of use and replenish

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Personal Kanban

  • Why do unfinished tasks

bother us so much?

  • Zeigarnik Effect – adults have

a 90% chance of remembering interrupted and incomplete thoughts or actions over those that have been completed

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Personal Kanban

Get an

  • il

change Paint Spare Bedroom Call your mom Get Kids to Practice Update Website

Schedule Quarterly Meeting

Pay Bills Reserve Room

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Personal Kanban Rule #1

  • Make work visible

– You can’t manage what you can’t see – Visuals communicate more faster – Provides context – helps prioritize and make decisions – Facilitates communication, coordination, and collaboration

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Personal Kanban Rule #2

  • Limit work in process (WIP)

– Increases efficiency (multi‐tasking is a myth) – Improves quality and reduces errors – Reduces stress – Facilitates learning (process, integrate, improve)

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Capacity vs. Throughput Capacity: how much stuff will fit Throughput: how much stuff will flow They are not synonymous

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Personal Kanban

Get an

  • il

change Paint Spare Bedroom Call your mom Get Kids to Practice Update Website

Schedule Quarterly Meeting

Pay Bills Reserve Room

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Personal Kanban

  • Things to notice as you start pull

– How long certain tasks take – Who you work with

  • People/Departments

– Which tasks get delayed

  • For review, approval, additional or missing info

Are there any continuous improvement opportunities?

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Adapt and Learn

  • Adapt as often as you need to
  • Adjust WIP

– Avoid too much multitasking (counter productive)

  • Create extra columns

– Waiting, set, etc.

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Example

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Multiple Uses

  • Improvement ideas
  • Meeting agendas
  • Personal development
  • Team’s regular work
  • Special projects
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Personal Kanban

  • Productivity: getting more done

– We get more done by limiting our WIP

  • Efficiency: doing it with less effort

– By focusing on our visuals we expend less effort

  • Effectiveness: getting the right things done

– By making informed decisions with pull, we get the right work done at the right time

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Create a Personal Kanban

  • 1. Decide key milestones (ready, doing, done –
  • r…)
  • 2. List the work waiting to be done (individually
  • n stick notes)
  • 3. Set work in process limits (usually 3‐5)
  • 4. Pull work in WIP and begin
  • 5. Use, learn, adapt!
  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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LEAN DAILY – GEMBA WALKS

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Gemba

  • Where the work takes

place – “the real place”

  • Go “see” first hand,

with own eyes what is really happening vs. what you assume is happening

Gemba is wherever the ball is.

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Purpose

  • Learning opportunity for walker

– Test actual reality against your assumptions – More deeply understand what’s really happening

  • Separate process and people performance

– 85%+ performance problems are process issues

  • Gemba Walks can change the culture

– People are afraid they will get blamed – Change the way you talk about improvement – Foster more critical thinking

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Relationship Building

  • Learning opportunity for people visited during

the walk

– Better understand why their work is important – Improve critical thinking skill and confidence – Increase trust with leadership

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Key Activities

  • Prepare for the walk
  • Do the walk

– Go See – Ask ‘What’ and ‘Why’ – Show respect

  • Debrief the walk
  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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LEAN DAILY – 5S

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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What is 5S?

  • 5S is the name of a workplace organization

method that uses a list of five Japanese words: seiri, seiton, seiso, seiketsu, and shitsuke

  • Translated into English, they all start with the

letter “S”: –Sort, Set in Order, Shine, Standardize, and Sustain

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Why use 5S?

“You and/or your co‐workers spend too much time looking for items you need to do your job: files, materials, equipment, office supplies, etc.”

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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5S Overview

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Sort

  • Remove unnecessary things
  • Applying the Sort function to your office

means that you will:

– Sort through everything on, in and around your desk – Separate or remove items that are unnecessary or in the wrong place

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Strategy

Toss Keep Move

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Red Tag

  • Items that need to be

removed but cannot be removed right should be red tagged

  • Fill out the red tag

information and affix it to the item that needs to be removed

Red Tag No.

Date Person Item Description Disposition Quantity Move Scrap Return Store Offsite Other__________________ Comments

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Desktop

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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LeanOhio Storage Room

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Set in Order

  • Arranging necessary items for easy and

efficient access – and keeping them that way

– Where does it make the most sense to store this item? – How will I recall this file when looking for it in my filing cabinet or on my hard drive? – Is this an item that I use frequently?

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Set in Order

  • Once you have eliminated all the unneeded

items, turn to the left over items

  • Set everything in proper place for quick

retrieval and storage

  • Arrange things is such a way that the most

frequently used items are the easiest and quickest to locate

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Before After

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Shine

  • Cleaning everything, keeping everything clean,

and using cleaning as a way to ensure that the area and equipment are maintained, as they should be.

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Cleanliness Statistics

  • Survey of over 1000 workers (Adecco)

– a majority of Americans (57%) admit they judge coworkers by how clean or dirty they keep their workspaces – Typical employee spends 2.5 hours a day searching for information – 80% of what goes into a filing cabinet is never referenced again

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Benefits of a Clean Desk

  • Save time and money

– Typical employee spends 2.5 hours a day searching for information – Average employee makes $26.00 a hour, a 800‐ person agency loses approximately $13.5 million a year from the inability to locate and retrieve information

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Standardize

  • Creating guidelines for keeping the area
  • rganized, orderly, and clean, and making the

standards visual and obvious

  • Standardize processes, make things consistent
  • Create rules for cleaning and maintenance
  • Determine the best way to do something and

do it consistently

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

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Sustain

  • Define how to maintain the best way
  • Develop good work habits that will continue
  • ver the long term
  • Culture change
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Ways to Sustain

  • Monthly area review
  • Reminders in staff meetings
  • Reward areas
  • Recognize improvement
  • Annual clean up day
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LEAN DAILY – POKA YOKE

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Why Use Mistake Proofing

“We get inputs from customers or from other sources (from paper forms or online web forms), we often find that the incoming information is incomplete or inaccurate.”

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  • Poka-yoke is a Japanese term that

means "mistake-proofing“

  • To correct mistakes before they happen

Mistake Proofing is everywhere from our home, to our car, to our work

Poka-Yoke Definition

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Three Rules for Defect Detection

Your Supplier Don’t accept defects You Don’t make a defect Your Customer Don’t pass on a defect

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How does Poka-Yoke apply to Government work?

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  • Almost every government process involves a form
  • During scoping, almost every Kaizen team is frustrated

that users of their services can’t complete a simple form (What an idiot!)

  • During a Kaizen event almost every team identifies

waste in in the area of the process that involves forms

  • More than 95% of State of Ohio Kaizen Event teams to

date have implemented improvements that reduce mistakes, delays and frustration around forms

Government Forms

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Love/Hate Relationship with Forms

  • The more information the

better

  • The bigger the words the

more impressive

  • Completely familiar with

all the jargon and issues

  • The longer the form the

more frustrating

  • The bigger the words the

more likely to confuse

  • Unfamiliar

Government Loves Citizen’s Hate

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  • What percentage of times is the form completed with

no errors?

  • How many errors are made?
  • How much time is spent reviewing the form and

correcting errors

  • Create checklist to breakdown errors by type or by

question

  • Create a Pareto Chart or Concentration Diagram
  • Look for Root Causes
  • Test / Implement solutions
  • Review how many, how often, what kind and how long

Use DATA for Mistake-Proofing Forms

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Concentration Diagram

Concentration Diagrams are great ways to collect data for your forms

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Concentration Diagram

  • Put data in a visual form

for all to see

  • Entire team sees exactly

what is being tracked

  • Visibility helps

employees prioritize issues and develop ideas to eliminate root causes

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  • Review missed questions with employees

and with customers

– Create a focus group

Next Steps

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  • Review statute, code, rules to see if you

really, Really, REALLY need to ask the question

Next Steps (con’t)

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  • Have you ever tested the reading level
  • f your forms, letters or website?
  • Use software to test the age level and

readability of forms

Next Steps (con’t)

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

lean.ohio.gov

How to check the reading levels

Microsoft Word has reader level features:

Go to the Spelling and Grammar Page of the Tools/Options Menu and checking “Show Readability Statistics.”

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Understanding Readability Scores

  • Looks at # syllables and # words per sentence.
  • Flesch Reading Ease Test: the higher the score, the

easier it is to understand. You want the score to be between 60 and 70.

  • Flesch-Kincaid Grade Level Test: rates text on a U.S.

school grade level. For most documents, aim for a score of approximately 7.0 to 8.0. Bulleted Lists are GREAT!

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Potential Improvement Ideas

  • Remove unnecessary questions
  • Explain questions that may seem unnecessary
  • Eliminate unnecessary typing with pull down menus

if online, or boxes to check if a paper form

  • With pull down menu, ensure most common

answers are first

  • Highlight required fields
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Potential Improvement Ideas

  • Online forms can’t be sent if information is left

blank

  • Create an FAQ or checklist to accompany the form

that explains to customers exactly what is needed. (Make most frequently missed questions the first thing on the checklist)

  • The most important questions are highlighted or in

a prominent location

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LEAN DAILY – STANDARD WORK

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Standard Work

  • The best known way that everyone does the

work

  • Definable, repeatable, and the results are

predictable

  • Ensure that waste is removed from the

process

  • Ensures that everyone follows the method

until a better method is defined

  • Enables challenging, yet achievable work
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Why Standardize?

“Variation is Evil!” ‐ LeanOhio “Without standard work, there is no Kaizen.” (continuous improvement) ‐ Taichi Ohno, The Toyota Production System, 1988

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Standard Work

Standard Work is created by those that “do” the work.

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How Can Standards Help?

  • Standard Work is a term coined by Toyota to

represent the established best way of performing work within a process. The

  • bjectives are to:

– Reduce variability (waste) by ensuring that everyone performing the work uses the same best methods – Share knowledge gained with the rest of the

  • rganization so that future improvement efforts

will be more productive.

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What to Standardize

  • Processes

– Checklists – Best Practices – Visual Management

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How to Snip a Picture of Your Screen

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Keys to Standardization

  • 1. Don’t Force Standardization
  • 2. Standard Work is created by those who do

the work

  • 3. Make standards flexible
  • 4. Its not always a long detailed procedure
  • 5. Make work as visible as possible
  • 6. No longer Standard – Ask Why?
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PDCA

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What is PDCA?

  • Simple standardized method of improvement
  • Repeatable and consistent
  • Serves as over‐arching model for all other

improvement tasks

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Plan Do Check Act

Identify & Select Problem Define current state Define future state Select & Plan Solution Action Plan – Test solution Check results Follow‐up Action Analysis Monitor

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When to Use PDCA

  • As a model for continuous improvement
  • When starting a new improvement project
  • When developing a new or improved design of

a process, product or service

  • When something bugs you
  • Your customers are complaining
  • You find yourself saying, there’s got to be a

better way!

  • When implementing any change
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PDCA Procedure

  • Plan. Recognize an opportunity; understand

the issue; plan a change

  • Do. Test the change. Carry out a small-scale pilot
  • Check. Review the test, analyze the results and

identify what you’ve learned

  • Act. Take action based on what you learned:

– If the change did not work, go through the cycle again with a different solution – If you were successful, standardize and incorporate what you learned from the test into wider changes. Monitor

  • results. Plan new improvements, beginning the cycle again

Plan Do Check Act

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Plan Do Check Act

Identify & Select Problem Define current state Define future state Select & Plan Solution Action Plan – Test solution Check results Follow‐up Action Analysis Monitor

  • SIMPLER. FASTER. BETTER. LESS COSTLY.

lean.ohio.gov

A‐3

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What is an A3?

  • Comes from the paper size

– 11” X 17” is an A3

  • Problem solving and planning tool
  • Consensus building process utilizing a

systematic, documented methodology

  • Communication tool for day‐to‐day problem

solving

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Why Use an A3?

“When my co‐workers and I talk about our work and our overall work process, we talk mostly about negative things: delays, rework, overwork, red tape, confusion, and so on.”

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A3 Thinking

  • A3 provides a structured format for problem‐

solving

  • Provides a method for addressing the things that

“bug” you or frustrate you

  • Reflects the philosophy of don’t blame the people,

fix the process!

  • A3 is all about continuous improvement
  • The first step is to really understand the problem.

Go to the Gemba, ask questions, get data

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A3 Report

Title: Date Started: Current Date: Team: Executive Sponsor: P1: Why change is needed P4: Analysis C7: Check Results P2: Current State P5: Potential Solutions A8: Follow‐up action . P3: Future State D6: Action Plan A9: Monitoring

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A3 Report

Title: Date Started: Current Date: Team: Executive Sponsor: P1: Why change is needed P4: Analysis C7: Check Results Why are we working on this problem/opportunity? What is the business case? What is the pain point? What is the impact? Scope? What is preventing achievement of the goal? What is the root cause or causes of the problem? Fishbone or 5 whys. Collect data. Check the results

  • f your improvement. Did you

close the gap? P2: Current State P5: Potential Solutions A8: Follow‐up action What is currently happening? Extent of the problem? Data. Statement of the problem. Graphically present a picture

  • f the current state.

Brainstorm solutions. Analyze

  • them. Select a solution to test.

What went well? What didn’t? If you didn’t achieve goal, then go back to test another

  • solution. If goal is achieved,

put into standard work. P3: Future State D6: Action Plan A9: Monitoring What specific outcome is required? What is the goal? What is the gap? Specific improvements in performance needed? Pictures/graphs Develop an action plan for running your test (or pilot) and implement it. What is the plan for ensuring that solution benefits are maintained? How will you monitor?

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Date: 1/28/2013 VP DIR MGR MGR OWNER Approval:
  • I. Theme: Improve PLL Expense
A3 REPORT ‐ PROPOSAL
  • V. Recommendations
* Implement a phone tree to reduce numbers and complexity on reaching an interpreter.

* Implement a video rollover where users can directly link into the next available interpreter using video carts. * Create/distribute MC badges with one phone number for any IS and which numbers to push for a specific language. * Hire "casual" Nepali interpreter to off set PLL Nepali expense ‐ further reduces costs to PLL. * Create/distribute new informational sheets to all departments and areas with contact info for quick reference to Staff * Change MC Interpreting Services business hours to increase capacity to offset PLL volume coming back in. * Distribute new language access plan * Create control plans to sustain and improve Interpreting Services service (Rounding, Video Cart Maint, Info Classes monthly, Tier Accountability Board (completed))

  • VI. Implementation Schedule

Action Start Date Completion Date Owner

  • II. Background/Current Situation

Implement phone tree w/ IR 1/2/14 1/30/14 Todd Huff Implement video rollover 5/31/13 3/1/14 Kristen Ordille Create/distribute new IS badges 1/6/14 3/1/14 Shannon Pinckney Improve/update IS website 1/31/14 1/24/14 Todd Huff Update IS Policy/Procedure 1/21'14 1/29/14 Todd Huff Hire Nepali casual 11/13/13 2/24/14 Todd Huff Lead info class at MCSA (top depts) 11/13/13 3/1/14, 4/1/14, 5/1/14, Todd Huff Lead info class at MCW (top depts) 11/13/13 3/1/14, 4/1/14, 5/1/14 Todd Huff Lead info class at MCE (top depts) 11/13/13 3/1/14, 4/1/14, 5/1/14 Todd Huff Create SWIs (Video/Phone, etc) 12/12/13 2/14/14 Todd Huff Items Completed:

)

Distribute surveys to staff/depts ‐ 12/19/13 Todd Huff All staff rounding ‐ 12/19/13 Todd Huff

  • III. Goal

Daily maint on video carts ‐ 12/19/13 Todd Huff Daily Tier Accountability Board ‐ 12/10/13 Todd Huff Update Administrative IS Policy 1/21/2014 1/29/2014 Todd Huff Information Sheets ‐ Quick Reference for Department Common Areas 1/20/2014 1/24/2014 Todd Huff

  • IV. Investigation/Analysis
  • VII. Evaluation

In order to get back to budget (or more), the goal is to "decrease PLL expense (during business hours) from average ~$12,500 (from beginning FY14) to ~$8,500/month by 06‐30‐14 and to $6,500/month by 12‐31‐14 while maintinaing/improving productivity.

Customers can call PLL directly for Interpreting Services by using a MCHS account

  • number. PLL only offers phone service. PLL is normally used for off hours and

lesser languages

Gemba Walk / Interviews Themes through MCSA (OB/GYN, Mother Infant, and Delivery) ************************* * Users use PLL because its easier and less steps * Users not aware of IS policies * Website is not useful and many do not know about it. * Neplai interpreters are needed * Gaps in the on‐boarding process informing nurses on IS.

Primary Measure Secondary Measure

Actuals Y-T-D Budget Y-T-D Budget Volume Adj. $ Variance Y-T-D % Variance Y-T-D Prior Y-T-D Controllable Expenses Other purch fees / services (PLL Expens 117,965 83,011 83,077 34,888 42.0% 80,994

Lack of user knowlegge Want real intereprters No connection Lack of training Standard of practice for video cart placement High turnover rate Website not up to date Lack of exposure of IS in orientation Too many steps for service Problems not reported Software Issues Don't like current pager system Missing IS instructions Missing Carts Lack of IS policy knowledge Misplaced carts and phones Video equipment not working Need Nepali interpreters PEOPLE MATERIALS PLL Reduction - Cause & Effect Diagram PLL Expense > Goal

GREEN on Interpreting Services Productivity

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SOLUTIONS

What solutions will solve the root causes? (Tools: Brainstorming and Affinity Diagram)

  • What solutions are best and we should recommend?
  • Tool for a few primary options: Impact/Difficulty Matrix
  • Tool for many options: Criteria Decision Matrix
  • Consider including an evaluation of the status quo (no change) option
  • What impacts (positive and negative) may result from implementing the solutions? (Tool:

Impact Wheel, FMEA)

  • How will we mitigate or resolve negative impacts?
  • What communication or stakeholder engagement is needed? (Tool: Communication Plan)
  • What training is needed?

ACTION ITEMS

  • What tasks or actions do we need to take? Who will be responsible for the task? When

should the task be completed? (Tools: Action Plan, Gantt Chart)

  • What support and resources are needed for each task?

METRICS/FOLLOW‐UP

  • What metrics will we use to track progress and performance? How will we validate results?
  • How and when will we check progress and performance (e.g., daily, weekly, 30, 60, 90‐

days)?

  • What processes will we use to enable, assure, and sustain success?
  • How will we communicate results and share what we learn with others?

Task Owner Proposed Date Actual Date

<Title>

<date>

BACKGROUND / BUSINESS CASE

  • What issue or problem do we need to solve?
  • Why is this issue important to solve now?
  • What benefits do we anticipate from solving the problem (e.g., quality, timeliness, cost,

customer/employee satisfaction)?

STAKEHOLDERS

  • Who are internal and external customers?
  • Who are team members that will complete the A3 Problem Solving Tool?

CURRENT CONDITION

  • What do we know? What customer, process, program data/measures do we have on the

problem (location, patterns, trends, frequency, factors)? Answer questions like: What errors are occurring? Who is making the errors? Where are the errors occurring? When are the errors occurring? How are the errors occurring?

  • What don’t we know and need to find out? We may need to develop a Data Collection Plan

that includes: The information/data we need to collect, who will collect the data, data sources, who will prepare the visuals (bar chart, trend, pie chart), when and who will be sent the data.

  • What is the Problem Statement? What specific performance measure needs to improve?

We need to understand the scope and nature of the problem before we can create a problem statement. More analysis may be needed if the team cannot write a problem statement.

  • Example: Reduce/Increase the number/percent of <?> from <current level> to

<desired level> by <date>.

ANALYSIS/ROOT CAUSES

  • What are root causes? Why are the errors occurring?
  • If the root cause is not obvious, use a root cause analysis tool. Use the simplest

tool to show cause‐and‐effect down to the root cause(s). The root cause should be specific – not vague like “poor communication”.

  • Tools: 5 Whys, Fishbone diagram, or Affinity and Relations diagrams
  • Does our data verify the root causes? – a team may need to collect additional data to

verify the root cause(s)

<Name>

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WHAT’S NEXT?

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Start Practicing Lean

  • Engage your coworkers

– What opportunities for improvement have you noticed? – Is it process related? – Develop creative solutions – Connect with other Lean‐trained people at your agency

  • Apply a tool at work and/or home
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Additional Training Opportunities

White Belt

  • 3 hour Lean awareness training

Yellow Belt

  • 1 day Lean daily overview

Camo Belt

  • 4 days + demonstration of learning
  • Lean tools for government

Green Belt

  • TBD

Black Belt

  • TBD
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Lean Liaisons

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