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Lean Champion

Bootcamp V.
ESAB India, Chennai
19th 30th July
2010

Safety

SAFETY
COMES
FIRST !!!

I Could Have Saved A Life Today


I could have saved a life today, but I chose to look the other way.
It wasnt that I didnt care, I had the time, and I was there.
But I didnt want to seem a fool, or argue over a safety rule.
I knew hed done the job before, if I called it wrong, he might get sore.
The chances didnt seem that bad, Ive done the same, he knew I had.
So I shook my head and walked on by, he knew the risks as well as I.
He took the chance, I closed an eye, and with that act I let him die.
I could have save a life today, but I chose to look the other way.
Now every time I see his wife, Ill know I should have saved his life.
That guilt is something I must bear, but it isnt something you need to share.
If you see a risk that others take, that puts their health or life at stake.
The question asked, or thing you say, could help them live another day.
If you see a risk and walk away, then hope you never have to say,
I could have saved a life today, but I chose to look the other way.

Introductions / Creature Comforts


Toilets
Smoking
Refreshments
Fire
Mobile phones
Safety on the shop floor
Interactive Training Course

Ice Breaker..

The Team
Game

Introductions And Expectations

Verbally
Name
Site
Position
Responsibilities
Experience with Continuous Improvement
Questions / Expectations of Course

Course Objectives
To deliver a practical and detailed understanding of the Unipart Way philosophy,
principles, tools and techniques.
To gain a deep understanding of some of the core tools and techniques of the Unipart
Way through practical application.
To understand the importance and key elements of team working in a continuous
improvement culture.
Delegates understand how The Unipart Way supports and integrates lean principles into
their organisations overall business strategy.
Delegates leave with a plan for implementation of Lean at their site.
To support ESAB Indias lean activities by identifying, prioritising and implementing
further improvement opportunities and benefits that are sustainable.
Continue to develop a community of lean advocates.

Agenda - week 1
MON

TUE

WED

THU

FRI

SAT

19-Jul

20-Jul

21-Jul

22-Jul

23-Jul

24-Jul

08:00 Team exercise (visual mgmt) 08:00 Team Announcements


08:30 8 Step Strategy

08:00 Team Announcements

Facilitator feedback

09:30 Coffee

08:45 Factory presentations

09:45 MIFA

09:45

08:00 Team Announcements

Facilitator Feedback

Facilitator Feedback
Brief - Presentation and
storyboard

08:00 Team Announcements


Facilitator Feedback

08:45 5S

08:45

09:30 Coffee

09:00 Leading Change

10:15 Coffee

10:00 Coffee

09:45 Coach (hotel to plant)

10:00 Coffee

10:45 Presentation dry runs

11:45 Process mapping

10:15 Visual Management

11:15 Comm. Cell meetings

10:15 PDM

12:15 Lunch

12:15 Lunch

12:15 Lunch

10:45 SMED

11:30 High / low level MIFA

14:00 Opening speech - Hariharan

13:00 7 Wastes

11:45

Introductions

13:45 Insight Star (Video)

12:15 Lunch

Ice Breaker

14:30 One Point Lessons

Course Agenda
Team Working

MIFA Exercise

ESAB Way

Health and Safety


presentation

12:45

Lunch @ plant (breakout


rooms)

11:45 WPA

13:30

High / low level MIFA Contd

12:15 Lunch @ hotel

13:00 Coach (hotel to plant)

Process Mapping

13:00 Coach (hotel to plant)

14:45 Coffee

14:00 Plant tour

Insight Stars

14:00 Comm. Cell meetings

15:00 Comm. Cell

14:45 Data gathering:

Comm. Cell exercise (KPIs)

Project brief + issue data


packs

PDM exercise

High level MIFA

18:00 Coach (plant to hotel)


20:00 Dinner

KPI's

Future state maps

16:15 Introduction to Unipart

16:45 OCC / CPS

Construct comm. Cell

Benefits analysis

Team exercise (Visual mgmt) 18:00 Depart from Temple Bay


19:30 Dinner (Hariharan)

20:30 Dinner at City Hotel

17:00 Coach (plant to hotel)

15:00 Close

Finalise current state maps

16:30 Coffee

OCC Exercise

13:00 Present to ESAB India SMT

14:15 Process trials

16:00 Coffee

17:00 Need for Change

08:45 Presentation Preparation

Presentattion prep (photos


etc)

19:00 Reach Hotel & Fresh-up

18:00 Coach (plant to hotel)

19:30 Dinner (Mike Foster)

20:00 Dinner

Coffee Break @ Plant From 15:15 to 15:30 and the session will continue after the break

The agenda is subject to change at any time. Please


ALWAYS check with your facilitator

Agenda - week 2

The agenda is subject to change at any time. Please


ALWAYS check with your facilitator

Course Trainers
Sean Ferneyhough
UMEP Regional Manager

David Mead
UMEP Regional Manager

Course Support Team


Facilitator Team:
Chris Isherwood
Madhusudana
And
Team Facilitator
Andrs Talabr
Team Facilitator
Camilla Jarleskog
Team Facilitator
Simon Kennell

Syndicate Teams
SUNDAR
SUNDARLAKSHMANAN
LAKSHMANAN
RRVAITHAMANITHY
VAITHAMANITHY

CASE STUDY AREA


Extrusion

GANGULY
GANGULYAAKK
ABHAY
ABHAYDATTATRAYA
DATTATRAYABARIDE
BARIDE
RAJESH
RAJESHSURYBHANJI
SURYBHANJICHURAD
CHURAD
SUGENG
SUGENGRIYADI
RIYADI
EDDIE
EDDIEZHANG
ZHANG
ARUN
ARUNPRABHU
PRABHU

FACILITATOR
FACILITATOR
Andrs
AndrsTalabr
Talabr

Syndicate Teams
ANAND
ANANDTT
K.S.GANESH
K.S.GANESH

CASE STUDY AREA


Submerged Arc
welding
Flux plant

SUDIPTA
SUDIPTAGHOSH
GHOSH
PRABIR
PRABIRDAS
DAS
TAPAS
TAPASKUMAR
KUMARPATRA
PATRA
SSNEELAKANDAN
NEELAKANDANIYER
IYER
VISHWAS
VISHWASM.
M.KAMBLE
KAMBLE
YYUSUF
USUFSUPENDI
SUPENDI

FACILITATOR
FACILITATOR
Camilla
CamillaJarleskog
Jarleskog

Syndicate Teams
BISWADEEP
BISWADEEPBANERJEE
BANERJEE
GAUTAM
GAUTAMDHAR
DHAR
PARTHO
PARTHODEY
DEY
TAPAN
TAPANKUMAR
KUMARPAHARI
PAHARI
SANJIB
SANJIBDHARA
DHARA
SUBHRANGSHU
SUBHRANGSHUDAS
DAS
C.R.BALAJI
C.R.BALAJI
GGSSSRIRAM
SRIRAM
KAI
KAILI
LITAN
TAN

FACILITATOR
FACILITATOR
Simon
SimonKennell
Kennell

Team Awards
There will be three team awards. The three awards are:
1.Best Safety
2.Best Visual Management
3.Best Overall Team

Course Rules

This is a real opportunity to learn about The Unipart Way + Lean Manufacturing
All we ask is the following:

Set an excellent example of a champion that is committed to the successful implementation of


Lean Manufacturing.

Wear Team Colours with pride.

Wear all PPE where and when necessary.

Arrive on time for the bus if you are late the bus will go without you!!
- You will have to negotiate a time to rejoin the course and apologise to your team mates
your team will lose points

When in the factory arrive on timefor sessions, if late do not enter your facilitator will come
and find you.
- You will have to negotiate a time to rejoin the course and corrective action maybe taken!!

When on the shop floor please be courteous to the operators / foreman / management
- DO NOT STRAY ONTO THE LINES WITHOUT YOUR FACILITATOR!!

When in lectures no interruptions No mobile phones / pagers / Messages etc.

When in the hotel all team rooms must be locked and keys handed to reception by 22.00pm

Treat the hotel and the staff with respect and remember other guests are staying there as

Use the course as an opportunity to learn well!!


about the other factories and how they
plan to apply Lean Manufacturing.

Use the course as an opportunity to see how to effectively develop a successful


team.

Enjoy yourself and have fun!!

Lean Champion Accreditation Rules


All sections of the course are compulsory attendance.
Failure to attend any section will result in automatic failure of
the course.
If one day of the course has to be missed, then the whole
week has to be re-sat on the next available course (providing
space is available.)
For the exam, the pass mark is 70% (This equates to 30% of overall
mark)

If the candidate is a borderline pass/fail, they will be given an


oral examination by one of the Course Leadership Team.
Practical sessions are assessed through presentation of
activity boards. Candidates must reach a pass grade for the
board marking

Thought For The Day..


There Is Little Difference Between A Winner and A Loser

The winner thinks of reasons why he CAN do it.


The loser thinks of reasons why he CAN NOT do it.

This Small Difference Makes A Big Difference In Their Lives

Having A Short Mental Break


The Stretch Break

PLEASE
GIVE
MY
BRAIN
A
CHANCE

Final Course Presentation


1. Each team has 25 minutes for presentation and 5
minutes for questions
2. Each team should prepare the following:
a.

A full set of activity boards showing their activities over the two
weeks of the Lean Champion Boot camp course.
i. These boards are based on previously developed materials
ii. The boards should show any improvements and forecasted
benefits identified during the course
iii. A brief summary of ESAB Mor containing best practice
examples and priority areas for improvement.

b. Robust plans on how they are going to progress Lean in their


respective factories.

Team Working

WCM Instructor Programme

The Unipart Way

Team Working
Develop a team identify
Pick A leader
Define team roles
Have A Timekeeper
Carry out Briefing and
De-briefing sessions for syndicate work
Organize your room

Together
Everyone
Achieves
More

Team Exercise (1)


In your Teams please complete the following
Name your team and produce a logo
Bring your board to life!!
- use coloured pens / tape .etc
You have 30 minutes to complete this exercise

What is a Good Team?

Elements of a Successful Team

1.
2.
3.
4.
5.
6.
7.

Climate
Involvement
Leadership
Problem Solving
Decision Making
Communication
Conflict

Team Performance - Climate

Create an Atmosphere that is cooperative and supportive.


Clearly Defined set of Goals
An atmosphere free of fear, where everyone can offer ideas
without criticism.
Provide a comfortable room or setting where team members can
discuss, learn, and data gather.

Team Performance - Involvement

Everyone is involved and using their abilities.

No Rank Allowed, everyone is equal

Everyone is fully engaged

Team Performance - Leadership

Leadership can shift among team members to whomever has the


expertise for the particular task.
Democratic atmosphere where everyones ideas are sought and
utilized.
Team Leader for the day keeps the team focused and productive.

Team Performance - Decision Making

Attempt to make decisions by consensus. Assure that everyone


had their input and listened to the ideas and reactions of all.
All team members must support the team decision made, even
though they might not completely agree with the decision.

Team Performance - Communication

Keep Open lines of communication:

Good Listening skills are required


Always respond constructively
Provide all feedback in a positive manner
Let one person at a time talk so all can benefit from their information
Make Team Norms and stick to them

Team Performance - Conflict

Healthy conflict can spark a team to more creative thinking and


solutions.

Tuckmans Team Development Model

Dr Bruce Tuckman 1965

Team Development - Forming


High dependence on leader for guidance and direction.
Little agreement on team aims other than received from leader.
Individual roles and responsibilities are unclear.
Lots of questions about the team's purpose, objectives and external
relationships.
Processes are often ignored.
Members test tolerance of system and leader (team leaders beware!).
Leader directs.

Team Development - Storming


Decisions don't come easily within group.
Team members vie for position as they attempt to establish themselves.
The leader might receive challenges from team members (beware the sharks!).
Clarity of purpose increases but plenty of uncertainties persist.
Cliques and factions form and there may be power struggles.
The team needs to be focused on its goals to avoid becoming distracted by
relationships and emotional issues.
Compromises may be required to enable progress.

Team Development - Norming


Agreement and consensus forms among team.
Roles and responsibilities are clear and accepted.
Big decisions are made by group agreement.
Smaller decisions may be delegated to individuals or small teams within group.
Commitment and unity is strong.
The team discusses and develops its processes and working style.
There is general respect for the leader and some of leadership is more shared by
the team.
Leader facilitates and enables.

Team Development - Performing


The team is more strategically aware; the team knows clearly why it is doing
what it is doing.
The team has a shared vision.
There is a focus on achieving goals.
The team has a high degree of autonomy.
Disagreements occur but now they are resolved within the team positively and
necessary changes to processes and structure are made by the team.
Team members look after each other.
The team does not need to be instructed or assisted.
Team members seek personal and interpersonal development.
Leader delegates and oversees.

Team Development

Which stage will your team get to?

Engaging People in Team Working


Traditional Company

Lean Enterprise

What is the problem?

Result of someone
messing up

Deviation from standard

What is the cause?

Individual (5whos)

System (5 whys)

Who is responsible?

Person who makes


mistake

Management

What should the individual


who makes a mistake do?

Solve problem on own if


possible

Call attention to problem


for assistance and to avoid
the problem in the future

Assumptions about people

They will not accept the


blame unless forced to

They will feel empowered if


they get positive support
for solving problems

Problem-solving skill

Some have it, some dont

It can and must be taught

A Successful Teams Environment


ORGANISATION
ORGANISATION

PLANNING
PLANNING

Teamworking

Why are we interested in


Teamworking ?

The Unipart Way & Teamworking

LEAN
LEAN
LEAN

LE
AN

Unipart Way
focuses
TEAMS
on solving
Problems

Teamworking The Unipart Way


A competent and committed individual can make a significant
contribution to improving the business. However, when
individuals join together the potential is enormous:
The effect of the whole is greater than the sum of the
individual parts.
The Unipart Way emphasises the importance of teamworking
because;
A team can do more jobs an
individual cannot.

2 + 2 = 10

Team are more likely to produce


better results.

The overall time taken to identify, plan


and implement the required changes
successfully, will generally be less than
with the individual approach.

The changes required to improve


the business are more likely to be
accepted by the team involved and
the team is more likely to persuade
others to accept the changes.

Team building creates an environment


for personal development,
strengthening the organisation and
harnessing the individual potential for
further business

Teamwork is
Fun.

Team Exercise (2)


Red Team
Fire & Evacuation procedure hotel
Blue Team
Factory Health & Safety
Grey Team
Emergency Contact Numbers (Factory & General)
RULES: Cannot speak, use written words or numbers
Train other teams Tuesday 20th July, 8.00am (2 mins. max)