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Posts Tagged ‘plan do check act’

Getting more results from 5S Standardise & Sustain

Thursday, March 24th, 2011

By Paul Steven – KCTS Consultant

When working with a customer recently on 5S, they asked about taking the next steps after successfully completing 3S’s (Sort, Set-in-order & Shine) for the first time. In their eyes, all they needed to do was write up the standards on what to keep, where to keep it and how often to clean and that was job done. As I explained, the write up of such standards is very important but how were they to sustain, and even improve, these standards?

5S Standardise & Sustain

I explained my perspective to this customer, the Plan-Do-Check-Act cycle is a crucial element of sustaining all improvements. We must plan the physical changes and plan the documentation changes, just as they had, and then execute these plans. They had executed the physical changes and had yet to complete the documentation changes required for their first cycle of 5S. But once they have these documents, is that the end? Not when using Plan-Do-Check-Act, the Check-Act part requires us to review the results achieved from executing our plans and then act to attain more results, including better standards and better adherence to standards.

This had not been their perspective, but they were convinced once we discussed their next continuous improvement strategies. 5S has one of the best return-on-investments of any improvement strategy. This is in part due to its very simple conceptual model. This model can be applied to any area, real or virtual (such as when applying to IT systems rather than work places). The power of 5S is that you can continue to improve results without increasing the complexity of the model, no further training, nor confusion over tools, but merely focusing on more detail within the area.

The next steps for the customer related to fully integrating the changes across their 3 shifts. The people involved in the changes were from a single shift and whilst they had committed to the changes made, both physically and via the upcoming documentation, what about those with less involvement? Check-Act gave an opportunity for them to become involved, the next cycle could build upon the areas where they continued to have ambiguous or missing standards. This is what Standardise and Sustain is all about. We must create a baseline for further improvement.

They were persuaded that reviewing the standards was not failure but in fact part of the process. This change in perspective allowed the truth on some of the short-cuts taken to come out. The consultation method on items locations, which we had agreed before executing the plan, had not been as thoroughly used as they would have been preferred. They also noted that there was much that could still be found around the entire area to improve.

My customer is now excited that Standardising allows them this baseline to move forward and that Sustaining is all about supporting the next cycle of Sort, Set-in-order & Shine by capturing enthusing the teams to use and report their finding every day on the standards in their area. This data can came via audits or using people’s experience written onto Team Boards. Each team can find ways to improve the standards they use every day once Plan-Do-Check-Act is embraced.

If you would like to know more about delivering change everyday through your own people, please contact us here.

Are you using Self Assessment Audits to drive your success?

Thursday, February 3rd, 2011

Written By: Paul Steven – KCTS Consultant

To control the quality of your products it is necessary to have an excellent understanding of the processes within your business. How are you judging your process performance?

Judging process performance of your systems can be measured externally and give you benefits, and it can be measured internally and give you different benefits. External audits can be objective, observation based and external audits measure a process compared to proven practices and experience. Internal audits can allow a much deeper understanding of the health of a process by assessors who use the process as part of their daily life.

Self Assessment is the process of allowing you to use a standardised audit to measure your process against an aspiration. Externally supplied Self Assessments allow you to measure your own progress against industry-standard aspirations or philosophical aspirations. Internal Self Assessments, especially when written yourself, allow you to measure the success of a process against internal aspirations.

Recently I have had the privilege to work with a customer on converting an external Self Assessment, supplied by KCTS, into an internal Self Assessment aligned to the company’s aspirations for the next 2 years. This allowed the language of the audit to be altered and the direction given by the company to be woven into the questions. This particular Self Assessment dealt with 5S, a subject close to my heart, and related to whether the process was truly embracing the Plan-Do-Check-Act philosophy needed to sustain and improve 5S within the workplace. My customer was at first keen to include specific documentation audits as a way to assess the success of the 5S processes, but as we discussed 5S processes and Plan-Do-Check-Act the need to evolve the processes became evident. This internal Self Assessment must look for the evidence of delivery of the process more than restricting it to a documentation checklist. Self Assessment allows reflection on whether the processes or the personalities are driving successes.

The resulting internal Self Assessment also has clear scoring criteria to allow every person within the area to understand and judge their current performance within the process. Targets are being agreed to ensure the audit is progressive. Self Assessment requires discipline to ensure that the score does not rise based on a need to show progress as openness must be the priority whenever Self Assessment is deployed.

To summarise, external assessment allows you to be compared to others but when written correctly Self Assessment allows you to compare yourself against your own aspirations.

 

 

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