Before you can improve anything, you need to know where you are and what you want to achieve. A thorough assessment of your current manufacturing state can help you identify the gaps, strengths, weaknesses, opportunities, and threats of your processes. You can use various tools and methods to conduct this assessment, such as value stream mapping, SWOT analysis, or benchmarking. The assessment should involve all the relevant stakeholders and employees, and be based on data and facts, not assumptions or opinions.
Utilizo ferramentas como o Seis Sigma para identificar pontos de melhoria, analisar dados e implementar soluções eficazes. Ao enfrentar obstáculos, recorro ao método PDCA (Plan, Do, Check, Act) para garantir uma abordagem sistemática na resolução de problemas, assegurando que cada etapa seja cuidadosamente planejada e avaliada. A minha abordagem envolve também a promoção de uma cultura Kaizen, estimulando a colaboração de toda a equipe na identificação de melhorias contínuas. Ao adotar a mentalidade Lean, concentro-me na eliminação de desperdícios e na otimização dos processos, buscando constantemente alcançar a excelência operacional.
Anoto os principais pontos de melhoria, e discuto com as equipes e liderança, promovendo uma coletividade na resolução dos problemas. Busco ao máximo manter-me por dentro do processo, para contribuir com a tomada de decisões e o estudo de novas soluções com mais facilidade.
📌 Assessing your current state, prioritize continuous feedback loops and performance metrics to track progress and adjust strategies accordingly. Involve frontline workers in the assessment process, as they often have valuable insights into day-to-day operations. Furthermore, consider external factors such as market trends and regulatory changes that may impact your manufacturing processes. By embracing a holistic approach to assessment and incorporating diverse perspectives, you can develop robust improvement initiatives that address both immediate challenges and long-term goals effectively.
Structure the problem, make it easier to understand for the various stakeholder groups. Take plenty of time to understand the real problem. Build the necessary trust so that they get open answers. Take the risks the stakeholders see seriously. Question statements.
Make sure to assemble a team which represents all types of users. Without their input and buy-in, continuous improvement cannot happen.
Once you have a clear picture of your current state, you can set your improvement goals and objectives. These should be specific, measurable, achievable, relevant, and time-bound (SMART). You should also align them with your overall business strategy and vision, and communicate them clearly and consistently to your team and other parties. Your improvement goals should be realistic and attainable, but also challenging and motivating. You should also monitor and review them regularly, and adjust them if needed.
1) Identify Key Metrics: Determine which KPIs need improvement. 2) Utilize Data: Analyze historical and real-time data to understand current performance, identifying areas for enhancement. 3) Involve Stakeholders: Collaborate with teams to understand challenges and gather diverse perspectives in setting realistic improvement goals. 4) Prioritize Improvements: Rank areas based on impact and feasibility. Concentrate on critical areas to drive substantial improvements. 5) Set Specific Targets: Establish SMART goals for each metric, aligning with overall business objectives. 6 )Create Action Plans: Develop detailed strategies, assigning responsibilities, resources, and timelines to achieve the set goals.
🔑 Defining improvement goals, prioritize transparency and accountability by involving all stakeholders in the goal-setting process. Encourage collaboration and input from cross-functional teams to ensure alignment with diverse perspectives and expertise. Furthermore, establish key performance indicators (KPIs) to measure progress towards each goal and provide actionable insights for decision-making. Regularly review and celebrate milestones achieved, fostering a culture of continuous improvement and recognition. By engaging stakeholders, setting clear expectations, and monitoring performance metrics, you empower your organization to drive meaningful and sustainable improvements in manufacturing processes.
As metas precisam estar alinhadas à estratégia organizacional, além de serem alcançáveis e mensuráveis. Procuro sempre definir 2 ou 3 indicadores primários me baseando nos pilares de qualidade, produtividade e financeiro. À partir deles, crio outros 2 ou 3 indicadores secundários para acompanhamento. As metas alvo são definidas em conjunto com o time à partir de coleta histórica, considerando a projeção de benefício da melhoria e a meta estratégica da organização. Após implementadas mudanças, faço uma recorrência de análise dos dados dos processos, compartilho diariamente com o time, faço projeções e levo para apresentação e debate com o time. Não raras vezes encontro maneiras melhores de medir o processo.
Por pequeñas que sean las acciones llevadas a cabo, es fundamental valorar el impacto económico, cultural y/o reputacional de cada una de ellas.
Uma coisa que eu acho útil e uso sempre é fazer um planejamento baseado em fases. Você tem o objetivo claro no final, mas não perde tempo fazendo todo planejamento. Uso o lean startup como base. Crio sprints de 15 dias, nesses período temos claro o que será feito, fazemos, testamos e implementamos. Isso garante entregas parciais e flexibilidade para adaptar a semana seguinte.
To achieve your improvement goals, you need to implement improvement projects that address the root causes of the problems or inefficiencies in your manufacturing processes. You can use various improvement methodologies and frameworks, such as Lean, Six Sigma, or Kaizen, to guide your project implementation. These methods typically involve defining the problem, measuring the current performance, analyzing the data and causes, improving the process, and controlling the results. You should also involve your team and other stakeholders in the improvement projects, and empower them to suggest and implement solutions.
📈 Implementing improvement projects, foster a culture of continuous learning and experimentation within your organization. Encourage knowledge sharing and collaboration among teams to leverage diverse perspectives and innovative ideas. Provide training and resources to support employees in adopting new methodologies and tools effectively. Moreover, establish mechanisms for regular feedback and review to ensure the sustainability and scalability of improvement efforts. By embracing a dynamic and adaptive approach to improvement projects, you empower your organization to continuously evolve and drive excellence in manufacturing processes.
Do not forget that implementation is done by doing. Think about who is suitable for implementation early on in the project. Consider value, data and psychological impact patterns. Even good processes do not work automatically. Also construct good control loops. Think about how you will set up change management. Ideally, an improvement should be implemented by the production department itself, for example. Don't celebrate your success, celebrate the success of your employees.
The Kaizen event is not complete unless all parts of DMAIC have been executed. Identify key stakeholders and process owners in the early stages and follow up on a regular basis.
Uma coisa que achei útil é o envolvimento da equipe no projeto de melhoria, assim todos tem o conhecimento e engajamento na implementação e no controle do processo.
Continuous improvement is a cycle of learning and adapting, not a one-time event. You should always seek feedback and data on your improvement projects and processes, and use them to evaluate your results and outcomes. You should also embrace failures and mistakes as opportunities to learn and improve, not as reasons to blame or quit. You should foster a culture of learning and experimentation in your manufacturing organization, and encourage your team to share their insights and experiences.
If you could not figure out much in your reflection and assessment of your continuous improvement in manufacturing, you can solicit for feedbacks and draw out insights from your documentation of a failed project, so as not to repeat error again. Feedbacks provide you insight in areas that you need to focus on for an improvement.
In my experience! Learning from feedback and failures is an essential part of personal growth and development. It helps us understand what went wrong and how we can improve in the future. Embrace the lessons and keep moving forward!
Use lições aprendidas, consulte dados, defina o roteiro da estratégia e use a ação de melhoria como mecanismo de estabelecer a cultura de melhoria contínua na sua organização.
📍 Learning from feedback and failures, prioritize a mindset of continuous reflection and adaptation. Regularly review and analyze performance data to identify trends and areas for refinement. Encourage open dialogue and constructive criticism among team members to foster a culture of accountability and innovation. Furthermore, celebrate successes and milestones achieved, reinforcing positive behaviors and outcomes. By embracing feedback and failures as opportunities for growth, you cultivate resilience and agility within your manufacturing organization, driving sustained improvement and competitive advantage in a dynamic market landscape.
I think that we should approach this as we approach every improvement: define a target condition and experiment your way forward. Failure and setbacks are normal parts of the continuous improvement process. It should be normalized to talk about this and learn from every result - sucessful or not. The important part is to analyse and understand the causes and correct your course accordingly.
Continuous improvement can be hard work and require a lot of patience and perseverance. You should not forget to celebrate and reward your successes, no matter how big or small they are. Recognizing and appreciating your achievements and progress can help you maintain your motivation and enthusiasm, and inspire you to keep improving. You should also acknowledge and reward your team and other stakeholders for their contributions and efforts, and create a positive and supportive work environment.
✒️ Celebrating successes, foster a culture of continuous improvement by using rewards and recognition to reinforce desired behaviors and outcomes. Provide incentives such as bonuses, promotions, or professional development opportunities to individuals and teams who consistently contribute to improvement initiatives. Moreover, encourage peer-to-peer recognition and appreciation to create a sense of camaraderie and teamwork. By acknowledging and rewarding both individual and collective achievements, you strengthen morale and commitment to excellence, driving sustained improvement efforts across your manufacturing organization.
Celebrate wins early and often to build momentum, and also celebrate the ways in which you learned and improved following failures to strengthen the team and maintain momentum!
Sometimes, you may need external support and guidance to cope with the challenges and frustrations of continuous improvement in manufacturing. You may benefit from hiring a consultant, coach, or mentor who can offer you expert advice, feedback, or training. You may also join a network, community, or association of other manufacturing professionals who share your interest and passion for continuous improvement. You can learn from their best practices, experiences, and challenges, and exchange ideas and solutions.
External support brings new views and input. A experienced consultant or training facilitator will ask questions that your regular team does not even consider because "it has always been that way and it works". Further, external support changes up the routine, and training participants and team members are more likely to listen and pay attention.
Melhoria contínua traz consigo oportunidades pequenas como um Kaizen e programas de participação popular e oportunidades de maior complexidade que requer uso de ferramentas que proporcionem testes de validação e hipóteses, uso de automação e tecnologia que em ocasiões não fazem parte da expertise do seu negócio. Procurar um especializado em outas frentes pode ajudar a solucionar problemas complexos. Isso pode ser um prestador de serviço, um cliente ou um fornecedor. Não tenha receio em requer ajuda para obter o êxito. Alinhe as expectativas com a alta administração da organização.
Concordo que é necessário ter uma outra visão externa para orientar, dar apoio, compartilhar idéias, essa interação é ótima para desenvolvimento contínuo.
Continuous Improvement can indeed be challenging and often demand a high level of self-motivation. As Voltaire aptly stated, "Better is the enemy of good." Having a clear vision is crucial in this journey, along with embracing the lessons gleaned from less successful endeavors. It's a continuous process of learning and growth. To thrive in continuous improvement, openness, collaboration, drive, and empowerment are essential. These qualities are integral components of a specific leadership mindset required for success.
Try to see things from a different perspective. Don't analyse things only from your perspektive. Leave the comfort zone to get a fresh view. Try to get Vuja de moments instead of deja vu. Create a corporate mindset that provides a good basis for change. People like to stay in the calm zone. Get adventurers and rebels on board. It is important that questioning the status quo becomes part of the company culture.
Enfrentar los desafíos y frustraciones de la mejora continua en la fabricación puede ser difícil, especialmente cuando nos encontramos en la ‘meseta del potencial latente’, donde el progreso no es visible de inmediato. Es en estos momentos cuando es crucial recordar que los sistemas que implementamos son los que realmente determinan nuestros resultados, no solo las metas que establecemos. Mantener un enfoque en mejorar y optimizar nuestros procesos diarios, en lugar de obsesionarnos solo con alcanzar ciertos objetivos, nos permite crear un entorno más sostenible y adaptable. A largo plazo, esta filosofía nos ayuda a superar esas mesetas y a lograr mejoras significativas y duraderas.