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TRANSCRIPT
Yesterday, I introduced you briefly to TeamSAI
TeamSAI Consulting is a recognized leader in implementation of major change efforts with our MRO clients
Our work is often based on – Accelerated change methodologies – sense of urgency – Collaboration and involvement of client leadership, staff
and workforce – Clear improvement mandates and communication – Targeted metrics and improvement goals that are
broadly shared with the client work teams – Sustainable change supported by continuous
improvement methodologies
Importantly, the TeamSAI Principals all have a solid track record of successful change management in industry
– We developed and refined our successful consulting approach based on proven experiences
Before getting into some practical discussion for this audience, let me review a few examples of success
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Market Strategy Operations Maintenance, Repair & Overhaul Supply Chain Safety & Certification
Consulting & Advisory Services TEAMSAI CONSULTING SERVICES
CONFIDENTIAL & PROPRIETARY
Nearly half our engagements involve a significant change effort
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Market Strategy
Operations
Maintenance, Repair & Overhaul
Supply Chain
Certification & Safety
Lean implementation and improved kitting solutions for production improvement
Facilitated transition from Military to Commercial engine MRO production
Proof-of-concept web enabled model for hazardous materials handling & identification
Multi-million dollar reduction in inventory through improved warehouse effectiveness
Internal supply chain assessment and improvements to benefit productivity
Aftermarket and Post-Delivery Customer Support Strategies
Acquisition due diligence and strategic support
North American growth strategy including acquisitions
Comprehensive market analysis to support engine MRO growth plan
Helicopter MRO market assessment and strategy for growth
Hangar productivity and capacity improvements via LEAN
Improvements in Line Maintenance planning effectiveness
Lean application to thrust reverser over-haul lines to reduce turn-around times
Step improvement in turn-around time through process improvement
Certification and training for first Asian Airbus certified VIP Completion Center
New fleet integration and certification
Start-up and certification of Lynx Aviation
Accelerated ETOPS Certification
Medivac operations SMS evaluation and recommendations
ETOPS certification support, interior engineering & certification
Lean transformation support to Air Ops division to enhance operation excellence
Post-merger on-time performance improvement from 4th quartile DOT to 1st
Major cost improvement initiative to align with industry norms
New Aircraft Evaluation and selection
Comprehensive operations improvement initiatives for improved margins
What’s are the common threads relative to motivating change?
The MRO business environment is changing faster than ever – The good life of 2007 is gone forever and the business is changing rapidly
The North American commercial fleet is undergoing a significant renewal – Demand may be more erratic as airlines quickly adjust capacity for disruptive conditions – High retirements of older aircraft
OEM participation in the aftermarket is definitely growing
Independent MRO’s are faced with a squeeze play – Fleet renewal – Changing input from airlines – OEM competition – Intensified cost and performance pressures
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The aftermarket business challenge requires dynamic strategies and constant adjustment
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Major change efforts are never easy
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So,
what are the Critical Success Factors (CSF)
of successful change efforts?
#1 CSF – Having a compelling business reason for change
Compelling is the key word … the vision must resonate at all levels – Board of Directors – Leadership and staff – Workforce – Customers
Urgency is also very important … it creates a “burning platform” – Most people will participate if they understand the need…therefore communicating
effectively is key
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If the mandate is not clear for all stakeholders, risk of sub-optimizing the change effort is high
#2 CSF – Strong, committed leadership
The leadership model has to be about "leading change", including – Sending a clear and consistent message to customers and employees – Taking on accountability for results – Learning to manage in a new environment that will not always be intuitive – Communicating why change is necessary – Becoming an example and pace setter for the process – Removing barriers that impede the process
Organizational Development expertise may be required to accelerate the efforts
Recognize that all may not be able to adapt – Be prepared to take action if necessary … ignoring the issue significantly increases the risk
of failure
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While top leadership commitment is an imperative, lack of unity among all leaders can be a major obstacle
#3 CSF – Have a well planned and organized methodology
Extensively plan for the important elements of the effort – How to drive effective and lasting continuous improvement in the organization – How to establish a sense of urgency around the effort – How to unify the Leadership Team in setting the example and the pace for the
organization – How to gain buy-in and traction across the organization to build momentum – How to communicate what you are doing internally and externally
Use a proven methodology based on identified needs … and commit the required resources
– Process change – Lean – Theory of Constraints – Six Sigma – Or a unique combination of available tools!
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“Just go do it” is not a winning strategy
#4 CSF – Involve the workforce and/or staff
Those involved directly in the processes being changed know best how to improve it
There is a lot of wisdom in the old Chinese proverb – Tell me – and I will forget – Show me – and I will remember – Involve me – and I will understand (commitment)
If you are dealing with a unionized work environment, get the union leadership involved and committed to support (before you start!)
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Driving change designed by others without involving the workforce is a recipe for failure
#5 CSF – Develop clear metrics and accountability
What gets measured, gets done!
Clear metrics at every level of the organization is important – It is easy to have too many meaningless metrics – pick the right ones – It is easy to incent the wrong behavior with poorly goals – balance the approach
Clear goals that drive long term continuous improvement are essential – "Raising the bar" as improvements move the needle is important
Clear accountability for results is often best leveraged with regular review sessions
– Start with weekly reviews to develop momentum
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Own the process and the outcome for greater commitment and accountability
Let’s Summarize
Successful, sustainable, large scale change efforts are challenging for sure
The top factors common to success must be solidly in place
If you are thinking that there surely are more success factors, there certainly are – These are the some of the most essential early on
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#1. Compelling Vision
#2. Committed Leadership
#3. Planned Methodology
#4 . Employee Involvement
#5. Clear Accountability
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Getting started and creating the framework is often difficult
There may be a clear vision and solid leadership commitment, but developing the roadmap can often be a challenge
– Within the organization, there may not be the talent and skills to map things out – Within the organization, there is often subtle executive resistance
– Admitting there is room for improvement in "my" organization is a threat – Self interests can often get in the way of an objective plan – Corporate culture or inertia can often be one of the greatest challenges to overcome
If the vision for change results in improved market position, better customer relations and retention, or improved financial results, every day of delay can be creating a competitive disadvantage
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One question for this discussion today is how best to successfully get started in your company
In closing, engaging outside experts to help is sometimes important … TeamSAI often assists in designing an effort
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Project Steps Purpose Benefits to Client
Identify Client Issues
▪ It is imperative that we understand the objectives from the clients perspective
▪ Generally issues are centered around productivity and throughput although root causes are difficult to define
▪ Knowledge that the consulting focus is clearly aimed at the core issues impeding performance
Recommendations
▪ Based on the findings, we define the most pragmatic route to new levels of performance with defined performance measures
▪ Improvement initiatives are defined in a prioritized ranking to create a literal road map for implementation
▪ Confidence in having a clear roadmap for implementation and freedom to make the choice of internal vs consultant led implementation
▪ Confidence that you will actually get a quality product within your desired timeframe vs. a “rolling invoice” to address unfinished items
Rapid Assessment
▪ Our approach of generating minimal disruption with maximum results in clearest perspectives on the core issues
▪ The cost of discovery is relatively low assuring the investment is channeled to actual improvements in results
▪ Using our proprietary Rapid Assessment Tools, TeamSAI has perfected a comprehensive process to probe all aspects of an operation to identify root causes
▪ We get to the heart of the matter within one to three weeks to understand the nature and scale of the opportunity
Improvement Implementation
▪ TeamSAI has an effective Rapid Implementation methodology with a track record of sustained results
▪ We instill continuous improvement methodologies to ensure that the client can continue to reap results after the engagement
▪ Flexibility in approaching improvements
▪ Greater certainty of sustained improvements
▪ Comfort in having clear off-ramp decision points for consultant involvement
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THANK YOU!
Corporate Headquarters 1003 Virginia Avenue Suite 300 Atlanta, GA 30354 USA +404-762-7257 Contact: David A. Marcontell President & COO
TEAMSAI©2014 March 2014
Case study: BBJ Interiors & Aux Fuel System Installation Efficiency
The client company had recently been spun off as a result of the sale of a larger component of the business; the owners looked to improve performance on current lines of business to increase profitability and enable expansion into additional lines
The size of the company was such that precision regarding investment dollars was extremely critical – prioritization of opportunities was tantamount
The organization was fragmented and the culture was sensitive as the employees had experienced numerous ups and downs – careful consideration of operational changes was required
TeamSAI was engaged by the board to conduct an assessment with specific focus on improving the profitability of interiors & fuel tank installation
The approach to the assessment included reviews of project bid procedures, hangar operations, staffing, project management and planning, change order processing, and organizational design
Financial considerations were linked to each component of the assessment to ensure recommendations were prioritized appropriately relative to the leaderships desire to focus on profitability
TeamSAI was retained to implement a number of significant objectives including hangar planning, organizational redesign, and continuous improvement program implementation
An independent MRO with significant BBJ offerings looked to improve custom interior and auxiliary fuel tank installation turn times in order to increase hangar capacity and improve profitability
The assessment uncovered the fact that the fragmented organizational structure was creating a number of inefficiencies
Planning and scheduling processes were found to be inadequate relative to managing the large scale nature of the installations and status reporting was inaccurate and ineffective
Other inefficiencies, including hangar floor work processes, materials supply delays, and work team management were also addressed in the assessment
Ultimately, having been retained to support a number of the assessment recommendations, TeamSAI redesigned the planning and project management processes and implemented a continuous improvement program to enable the company to proceed with other recommendations on their own
The assessment concluded with the presentation of findings and a detailed roadmap for implementation
TeamSAI conducted an organizational redesign plan to ensure staffing was consistent with production requirements (note that this effort was not related to numbers, rather, it was concerned with having people in the right positions to support the operation)
A comprehensive continuous improvement program was designed and implemented at the facility which included training, work team management, opportunity prioritization, and CI event execution
TeamSAI developed and implemented new project planning and scheduling tools for hangar project (interiors) and trained staff on the use of these tools
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Situation Results and findings
TeamSAI’s role Deliverables
Case study: Maintenance Planning & Operations Assessment
A new management team required a thorough assessment of the maintenance planning operation to help define deficiencies which were driving excessive numbers of aircraft out of service
The company was required to meet minimum contractual readiness requirements in order to achieve revenue thresholds and was struggling with planning and coordinating maintenance activities in the field
TeamSAI was initially engaged to conduct a two week assessment of maintenance planning processes at the airlines operations headquarters
Following the assessment, TeamSAI was retained to implement changes to planning, redesign maintenance programs, and restructure supply chain logistics functions at the airline
A niche airline supporting government logistics and operating in remote regions required assistance to improve their maintenance planning capability and the development of processes to meet maintenance support needs in the field
The assessment found the client company was laden with legacy military procedures which had not been adapted to meet the needs of their new commercial business model
Planning cycles were repeated numerous times before maintenance was executed and requirements were often missed as a result of the confusion
The coordination of maintenance plans, parts, and support documents was poor and often resulted in excessive downtime
The assessment portion of the engagement concluded with a presentation of findings and recommendations
TeamSAI, having been retained to lead the execution of specific deliverables related to maintenance planning and programs functions, completed these initiatives on time and on budget thereby enabling the airline to improve its mission readiness capability by 30%
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Situation Results and findings
TeamSAI’s role Deliverables
Case study: Airframe MRO Turn-Around-Time Improvement
Heavy maintenance turnaround times were consistently exceeding plan with increasing dissatisfaction from its customers
The longer turn times were also creating other issues externally and internally Down stream customer slots were being
compromised and constantly pushed back Internally, mechanic overtime was being driven up Hangar capacity was being unnecessarily
burdened Total facility throughput was being constrained As a result, financial results were not being
optimized
TeamSAI was engaged to first diagnose the root
issues and to assist the client in establishing a successful proof of concept improvement effort to demonstrate the potential for the facility
The first phase of the effort was a detailed assessment of the heavy maintenance cycle including pre-planning efforts, pre-induction preparedness, production control and management, responsiveness and handling of unexpected issues, material and tooling availability, mechanic productivity, and related internal support from engineering, shops, etc.
Following the assessment, TeamSAI guided implementation of the improvement efforts with a core team in the client organization
A large independent airframe MRO was struggling to complete airframe heavy checks on time and budget affecting customer relations and hangar capacity
The assessment results identified a number of opportunities relating to a best in class comparison
TeamSAI provided recommendation with a rapid implementation methodology which was necessary to demonstrate the proof of concept
Implementation was conducted in two stages First, the supporting functional issues were addressed
including pre-planning methodologies, parts and tooling staging, shop turnaround issues
With the pre-induction issues corrected, the actual production cycle improvements were implemented
The first aircraft produced under the new process represented a 30% improvement on historical performance
The assessment phase of the engagement concluded with a presentation of findings and recommendations
The implementation phase involved regular briefings to top management but was really judged by the change in energy in the workplace and by the structural and process changes being made to support the operation in line with best in class operations
Finally, a roadmap was developed for the client to continue with the implementation across the other hangar bays
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Situation Results and findings
TeamSAI’s role Deliverables
Case study: Line Mx Capacity Assessment & Modeling
Limited hangar space and long segment lengths created an urgent need to execute maintenance in very short intervals to ensure aircraft availability
The company had previously executed a lean initiative in the hangar and line maintenance areas at Heathrow but was still struggling relative to maintenance planning and scheduling
Collective bargaining units were unconvinced that schedule adjustments were necessary to achieve optimal performance
TeamSAI was initially engaged to conduct an assessment of maintenance planning and execution processes at the airlines hangar operation at Heathrow
Specific emphasis was placed on deviations from the plan, the re-planning cycle, and hangar efficiency
Following the assessment, TeamSAI was engaged to build a mathematical capacity management model for the LHR line maintenance operation which was used to develop staffing schedules
UK based international airline sought to leverage Mx scheduling to improve efficiency and decrease aircraft down time
The assessment found the client company was staffed adequately, but improperly scheduled (i.e. insufficient staffing at the right times)
Root causes for the rescheduling issues were examined and it was determined many were the result of a lack of coordination and planning standards
TeamSAI was subsequently engaged to quantify and model line maintenance capacity based upon variations of staffing and schedules for upcoming negotiations
The assessment portion of the engagement concluded with a presentation of findings and recommendations
TeamSAI produced a comprehensive mathematical capacity management model for the Heathrow hangar and used this model to develop and implement changes in the planning process
Situation Results and findings
TeamSAI’s role Deliverables
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