Three Key Methods

to Unlock Continuous Improvement

Across Your Plant
Brandon Wright & Eric Hansen

Beyond Compliance
Webinar & Podcast Series for Process Manufacturers
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Plant Management Platform

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Before We Get Started

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Casual but Professional Format

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About the Presenters
Brandon Wright
Customer Success
Coach
Brandon has spent the
majority of his career in
manufacturing roles, from
food manufacturing to
biotechnology, textiles, and
more. He’s worked on the
floor and in management at
Pepperidge Farms, Chobani,
Dannon, Kellogg’s, and even
owned and operated a flour
mill.
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Eric Hansen
VP Customer
Solutions
Eric has been designing,
developing, delivering, and
improving business
optimization solutions in the
health care, supply chain
execution, and process
manufacturing and
distribution markets for over
20 years.
Agenda

● Strategies for approaching CI implementation at your

organization
● Improvement techniques and how to address inefficiencies as
part of the Continuous Improvement (CI) cycle
○ Constraint Analysis
○ Genchi Genbutsu & Kaizen
○ Statistical Process Control
● Stories from the shop floor (and ceiling)

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 There’s a lot in the CI toolbox
8 Wastes Pull System
Continuous Flow KAIZE
PDCA
5 WHYS AGILE Standard Work N
Value Stream
Gemba Growth Hacking Maps
Walks
TQM Just in
Time Continuous
Kata 8 Wastes Daily Improvement Software
Kanban Boards
Coaching Huddles Value

Muri, DMAIC LEAN Takt Time

Hoshin
Stream
Map

Mura, ISO 9000

Jidoka Catchball Kanri Lean
Muda Kanban
Six Start
boards Lean 6 Theory of up
Sigma
Sigma
Heijunka Constraints

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Does your CI Process follow a process?

Three key questions:

1. What is your process?
a. DMAIC, PDCA, Ad Hoc, etc
2. How is your process initiated? How is it focused?
a. Reactive, Proactive, Scheduled
3. How is your process reviewed?
a. Validation of outcomes, blindspots, periodic review
The best indicator of success in any venture is to have a
process and to manage that process.
-Brandon Wright

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Capability Maturity Model (CMM)

Capability Maturity Model

Originally developed in the late 1980s
and early 1990s as a means for the US
Department of Defense (DoD) to
evaluate its vendors’ ability to
effectively deliver on software
development projects.

As with any model, there are flaws,

but we’ll use it for a quick poll…

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Using CMM, what best describes your
facility?
This is the way… or one way
Step 5 Step 1

Update metrics, monitor Document the current state,

performance, report results and define ideal future state

Process
Improvement
Model
Step 4 Step 2

Monitor, iterate, Root cause analysis, solution

finalize, formalize testing & selection

Step 3

Implement solution

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Method 1: Applying the Theory of Constraints

Objective: Increase Throughput

● Theory of Constraints = Focus
○ Map the process flow you want to improve
○ Define the maximum output for each step in the
process
○ ID the constraint and impact if it were improved
● Now you know what to improve, and what the result should
be in terms of Throughput

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Story Time: Theory of Constraints

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Method 2: Genchi Genbutsu

Objective: Proper Problem Characterization

● Lean Principles - reduce or eliminate waste
○ Genchi Genbutsu - Go and See
○ Interrogate and study the data and compare to what
you observed
○ Kaizen events address and improve what you observed
● Evaluate improvements against the goal and expected
outcomes
○ Watch for unintended consequences

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Story Time: The Rafter Perspective

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How many CI projects has your facility
completed in the last year?
Method 3: SPC

Objective: Improved Predictable Performance

● An ounce of planning is worth a pound of recovery
○ Process Capability and Target Setting
● Statistical Process Control
○ Data vs. Insight
○ Automated collection & analysis
● Understanding what causes observed results

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Story Time: SPC in Action

● Top 5 poultry processor

○ Usability & digitization
challenge results in new data
visibility
○ Presentation of data draws
response
● SPC Validation Process

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Getting it to stick

Educate and Be present Update the

involve beyond the metrics…
employees project, and inspect
from the check in on what you
beginning the changes expect(check the metrics!)

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Q&A
More Resources at www.safetychain.com

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Maximize Performance

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MARCH: Poultry Federation Conference, Pack Expo East, Modex,

Plastics Tech
safetychain.com/resources/webinars-events/

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