benefits of a ci/lean culture
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BENEFITS OF A “CI/Lean” CULTURE
Rick Foreman
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Who is Federal Heath Sign Company?Who is Federal Heath Sign Company?•Customer-focused, full-service sign company since 1901•Multiple manufacturing locations•Nationwide Sign & Lighting Maintenance division•Specialty Re-imaging division•Diversified customer base•Flexible to meet customer needs•Strong financial track record•Growth oriented
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Nationwide SupportNationwide Support
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Markets ServedMarkets ServedAutomotive
Finance
Gaming
Hospitality
Corporate Identification/Custom
Petroleum
Restaurants
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What are the Possibilities?What are the Possibilities?
• Profitable Growth in a challenging economic environment?
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“CI/Lean” Culture Change“CI/Lean” Culture Change• Started @ Top – CEO/President Level• Established full time CI/Lean Development Leader• Assess Organizational Culture• Develop Implementation Strategy• Know the “why” & “purpose” • Develop Lean Leaders & Network• Engage, Connect, & Influence• Know your audience
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“CI/Lean” Culture Change“CI/Lean” Culture Change
Gemba
CEO & Sr. Mgmt
Middle Mgmt
Team
SERVANT LEADERSHIP STYLE SUPPORT
ENGAGE-CONNECT-INFLUENCE
ENGAGE-CONNECT-INFLUENCE
Customer & Stakeholder Satisfaction
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Deployment/Sustain StrategyDeployment/Sustain Strategy• Systematic Identification/Elimination of Waste• Go the “Gemba” – Engage workforce• Rigorous CI/Lean Book Club Process• Strong 6S: Everything has a place/in it’s place• Hands On Problem Solving: Ask why again and
again and again• Organizational learning• Maintain sense of urgency (tension)
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We’re Leaning
Things Out
The cumulative efforts of systematically identifying and eliminating waste continue to yield great results. (HOW?)Go See @ The Gemba
CI/Lean Office Key: Ask what are your biggest or most frequent frustrations or constraints?
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Are We Winning? Was it a good day?Are We Winning? Was it a good day?
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What Do We See?
• Engage through visual examples/stories outside of work environment
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Engagement/AccountabilityContinuous Improvement
Tasks Owner
Comments / Results / Why? / Reducing-Eliminating Which
Waste?
Re-arrange saw in metal area to be parallel to iron worker. Review need of rack in between metal fab & weld (more of a catch-all & labeling not close to actual condition)
11-Nov
7-Jan
3-Jan Sam
Open up flow from metal fab into weld area By opening this area up we saved 23ft per trip average 8 times a day saves 184ft a day.
Consolidate / remove storage racks in the receiving area to provide ample space for inbound freight without blocking the aisle . This requires extra travel distance for lifts / buggies carrying product to areas of the shop
17-Dec
7-Jan
15-Jan Tony
Eliminate conveyance / Wasted motion Keeps the aisle clean so we do not have to move something to get down the aisle opening up 143 sq ft of floor space
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Results• Texas Mfg Assistance Center Awards @ Two
Texas Facilities (TMAC Evaluator is a certified Shingo Examiner)
• Inventory turns up to a high of 18 from 9• Rev. per employee up to $250k from $195k• VOC ratings over 9 on a scale of 1-10• Variance reductions of 10%• Set-up reductions of 55%• Warranty under 1% of product revenue
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Key Points & Conclusion• Influence Behavioral Change: “Change sticks only
when it becomes the way we do things around here.” John Kotter, Leading Change Influence Cultural Change: "We don't have to
change, survival isn't mandatory" W. Edwards Deming Model the Way / Lead: “It is amazing what you
can accomplish if you do not care who gets the credit.” Harry Truman Continuously Communicate the “Why” & “How”:
A vision without execution is hallucination.