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Continuous Improvement Best Practices
Driving Continuous Improvement in Plant Safety
This is a three part article summarizing topics from M. Franz Schneider, CEO of Humantech Inc. of Ann Arbor, Mich., is an internationally recognized expert in human performance.
Many manufacturing and industrial companies attempt continuous improvement techniques to drive quality and reduce cost. A well-structured ergonomics initiative can be a powerful accelerator to both reduce costly musculoskeletal disorders and create rapid improvements in productivity.
Continuous improvement succeeds best on the notion that every employee is responsible for identifying and acting on opportunities for enhancing processes. It’s a powerful concept that can result in significant improvements in the short term and dramatic progress over time.
It’s also a powerful concept that can result in chaos. To be effective, your organization must move toward common goals at an agreed upon pace. One of the biggest barriers to achieving this simple synchronization is the verbiage used by different departments to identify their functions.
“We do safety,” says one. “Well, we do quality,” says another. “Yeah, well, we do order fulfillment,” says a third.
These old silos and job definitions will not let a company be agile enough to optimize the benefits of continuous improvement. In the ideal, everyone works on safety, everyone pursues quality and everyone assures order fulfillment.
The reality of continuous improvement is that a person’s job description is not a guarantee of future employment. Rather, the key is an employee’s ability to engage in daily improvement from multiple perspectives, accruing multiple benefits. Employees depend on ideas generated at the shop-floor level rather than pie-in-the-sky strategic business plans generated from 30,000 feet.
Gen. Colin Powell has a lifetime of experience in leadership in demanding situations. He always is clear that people closest to the frontlines should not be second guessed by people sitting in offices. “The commander in the field is always right and the rear echelon is wrong, unless proved otherwise,” Powell said.
He echoed many of the earlier thoughts of lean manufacturing guru Taiichi Ohno, the father of the Toyota Production System. “In our factories, we start our kaizen (continuous improvement) efforts by looking at the way our people do their work,” Ohno said.
Two leaders, worlds apart, recognized the essence of continuous improvement and achieving excellence: Sustainable gains cannot be achieved unless people on the front line/shop floor lead the improvement process.
The 30-Inch View
In their own words, Powell and Ohno are talking about what I refer to as the “30-inch view” of people and performance. At 30 inches – roughly the length of a worker’s arm, or the distance between a worker and his or her workstation – issues are dealt with conclusively on a one-by-one basis. At 30 inches, people converse, reach for tools and sit at computers. Unfortunately, many employees face multiple barriers to productivity, quality and safety within their 30-inch range of control.
Beyond 30 inches, people have difficulty reading, hearing, speaking and working. At more than 30 inches away, problems become less intimate and appear to be someone else’s responsibility.
With a 30-inch view on continuous improvement, the value of ergonomics to safety, quality, production and the ability to meet customer needs is evident.
When everyone in a company understands that value is added on the shop floor, not around fancy meeting tables, then that company is able to leverage its continuous improvement effort over an entire plant population and the 220-plus days that people work in a year. This is how Toyota, widely regarded as one of the world’s best companies with world-class facilities and processes, still implements more than 1 million improvements every year.
To be successful on such a scale, companies must overcome significant hurdles. But the good news is that when implemented correctly, continuous improvement becomes self-sustaining. When the shop floor drives and achieves visible gains (visible from 30 inches away, for example) on a daily basis, it is motivating and builds teamwork, resulting in even more improvement activities. Shop floor employees drive continuous improvement in numerous organizations in North America and companies benefit from the effort every day.
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