On kaizen Events the Teams must come up with solutions for the problems
exposed on VSM, after set the targets and scope of the loop you want to fix;
this must happen within a period of time of 5 days; obviously there are days
where the Team will be confused & frustrated; because is very difficult to
find the right solution is short time and with very low money or zero if is
possible; it’s a real challenge for them.
This is the way that I was trained by my Japanese Senseis and works very
well if you are working with companies that have high level of Maturity on this
types of Kaizen events; they knows the process already; makes the effort from
Monday to Thursday and by Friday the sense on success will compensate all the
efforts done, hours of frustration and sleepless to find the solution to their problems,
this is how the Kaizen events works.
"You are a fool if you do just as I say. You are a greater fool if
you don't do as I say.
You should think for yourself and come up with better ideas than
mine."
“Wits Don’t Work Until You Feel the Squeeze”
As consultant I teaches the Team; Tools and Techniques, to make the
changes and improvements happen such as Cell Design, SMED, Standard Work, Hanedashi
, Jidoka etc. all the Lean Tools and
Techniques that you already know.
And as consultant; if you want do your job well; you can’t give the
solutions to the Team; just guide them to find the right solution by themself
instead
However, I had to recognized that I could do more for the Team in order to
find the right solution in a proper and ways, more structured and faster, and
then I recall from my past experience; when I was Design Engineer the Training
called TRIZ (Teoriya Resheniya
Izobreatatelskikh Zadatch - Theory
of inventive problem solving - Started
with Altshuller’s interest in invention and
work in Soviet Navy patent office) , TRIZ was invented to creates
improvement on new designs or improve the current ones , (the process are
included as well) TRIZ has an structure very easy ; you have just to follow
those principles and you will came up with new solutions. (As everything the
experience is very important).
Therefore I started teaches TRIZ (summarized obviously) to the teams to
identified the right pad of solution during the Kaizen Events.
The solution does not needs to win the Nobel Prize; just to solve the
problem on the faster an less expensive but effective way.
In the 1960s and 1970s, Genrich S. Altshuller, the Father of TRIZ
; he categorized the solutions into five levels.
• Level one. Routine
design problems solved by methods well known within the specialty. No invention
needed. About 32% of the solutions fell into this level.
•
Level two. Minor improvements to an existing system,
by methods known within the industry. Usually with some compromise. About 45%
of the solutions fell into this level.
•
Level three. Fundamental improvement to an existing
system, by methods known outside the industry. Contradictions resolved. About
18% of the solutions fell into this category.
•
Level four. A new generation that uses a new principle
to perform the primary functions of the system. Solution found more in science
than in technology. About 4% of the solutions fell into this category.
•
Level five. A rare scientific discovery or pioneering
invention of essentially a new system. About 1% of the solutions fell into this
category.
There are also 40 Inventive Principles.
Here just one example; of how to reduce the cycle time, micro movements
and increase the productivity, the rules where simple; don’t buy anything or
call external supplier for this; use Try-Storming, the Moonshine tool room and follow
the method TRIZ.
Before.
After.
As final comment; the Consultant must find the way to help the Teams,
and maybe this means look out of the box of Lean Manufacturing tools as well.
I hope this help you in your next Project.
gracias hermano!
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