The Value of Employee Engagement

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Nicolas Ruhmann

How a manufacturing plant went about a 200%+ improvement in employee engagement / problem solving

Negócios Tecnologia

The Value of
Employee
Engagement
How to turn 600 people
into 4000+ improvements

Diabetes Care – Holdrege, NE

350,000 sq.ft
620 employees

Largest diabetic
syringe
manufacturer in
the world

Agenda
Handle a large volume of kaizen ideas through gradual
use of manual to IT solutions.
How to keep the program increasing quality and
quantity every year
How a rewards system can help to motivate
"Exceptional" kaizens and identify stand out employees
Think of Kaizens as problem solving practice for every
employee
To use Kaizen's as a coaching / mentoring opportunity
to increase management / shop floor cooperation.

In the Beginning…
• Most Companies Start with a
“Suggestion Program”
• Suggestions are fine, but actual
improvements are better..
• Improvements are great, but learning
from them is outstanding…
• Getting everyone to learn how to make
improvements while learning from
them – now that’s ideal.

Background
Kaizen
Action
Sheets
(KAS)

Started Manual
Lot’s of Training
Lots of Publicizing

Speaking of Publicizing…
• Keeping in a spirit of “Fun” the teams began creating posters
that often were spins on the popular “pop” culture
advertisements back then…
• The following slides show an example of just how “corny”
and how much fun our team members had getting into the
“Kaizen Spirit”.

1,000,000 Syringes out the door

$1000

1 Barrel on the Floor

$0.001

1 Accident Avoided

Priceless

Aren’t you glad you use KAS?

Don’t you wish everyone did.

I’ve got great News!

We saved a bunch of money
by switching to KAS!

What did this get us?
BD - Holdrege Submitted KAS
2000
1800
1600
1400
1200
1000
800
600
400
200
0

175% Increase!

2006

2007

2008

Remove the Constraint and…
BD - Holdrege Submitted KAS
4500
4000
3500

10 per emp

10 per emp

Another 123% Increase!

3000

6 per emp

2500

4 per emp

2000
1500

2 per emp

1000

1 per emp
500
0
2006

2007

2008

2009

2010

Implementation Rate of all ideas has run 97-98% since 2009

2011

Recognition Program
CI coordinator

Team Leader

KAS winner

Manager

BD Holdrege Kaizen reward program
changes every year.
2010 (small prizes for # of Kaizens)

2011 (Big Prizes) TV,BBQ,Laptops
2012 (Cash rewards) $50 - $350

Receive a certificate of appreciation
signed by Plant Manager and CI
Leader

Tip: Have Vision project every year on
how to engage associates in Kaizen
program

Holdrege FY12 Kaizen Program

• 4 KAS

• Reward Program

(Direct deposit with next pay-check)

•
•
•

Monthly lottery (random) drawing of $50
Monthly Exceptional drawing of $350
Quarterly Safety Kaizen drawing of $350

•

The announcement of the winner will be made during the next Monthly Business
Communication meetings and also in our Ultra Fine Times Newspaper.

Kaizen as a Management Tool
Plant Manager Leader Standard Work
Activity
Safety

Quality

Task
incident reports on any new injury
Perform BBS Observation for Team
Member
Change Control

Monthly Weekly

Daily
As Needed
Mon Tue Wed Thr Fri
X

X
X

review one CAPA implemented actions
where implemented (when applicable)

X
X

Attend a PVD Board Meeting
X

Morning Board Walk

Walk one whole Value Stream
20 Keys Audit one Line
(may piggyback w /staff)

X

X

X

X

Productivity Ops Review
Review TRS Process on one cell

X

X

X
X
X

CI Review

X

Inspire on KAS / SAR with team member

X

Review / Challenge Skills Matrix
Review an implemented KAS/SAR with
responsible employee on the floor
Review Lean Blitz on floor with team
Verify / Challenge WIP levels on in one
cell
Coach / Mentor a Subordinate through
solving a problem
Development Give positive feedback to at least one
employee
One on One with Managers

X

Kaizen

X
X
X
X
X
X

X

X

In Summary
Ensure project completion and share results
Encourage participation – be involved

Focus on 1 Kaizen at a time
Give feedback / communication
Develop a system (dB) to keep track of progress

Have Fun

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The Value of Employee Engagement

1. The Value of Employee Engagement How to turn 600 people into 4000+ improvements

2. Diabetes Care – Holdrege, NE 350,000 sq.ft 620 employees Largest diabetic syringe manufacturer in the world

3. Agenda Handle a large volume of kaizen ideas through gradual use of manual to IT solutions. How to keep the program increasing quality and quantity every year How a rewards system can help to motivate "Exceptional" kaizens and identify stand out employees Think of Kaizens as problem solving practice for every employee To use Kaizen's as a coaching / mentoring opportunity to increase management / shop floor cooperation.

4. In the Beginning… • Most Companies Start with a “Suggestion Program” • Suggestions are fine, but actual improvements are better.. • Improvements are great, but learning from them is outstanding… • Getting everyone to learn how to make improvements while learning from them – now that’s ideal.

5. Background Kaizen Action Sheets (KAS) Started Manual Lot’s of Training Lots of Publicizing

6. Speaking of Publicizing… • Keeping in a spirit of “Fun” the teams began creating posters that often were spins on the popular “pop” culture advertisements back then… • The following slides show an example of just how “corny” and how much fun our team members had getting into the “Kaizen Spirit”.

7. They’re Grrrreat!

9. 1,000,000 Syringes out the door $1000 1 Barrel on the Floor $0.001 1 Accident Avoided Priceless

10. Aren’t you glad you use KAS? Don’t you wish everyone did.

11. I’ve got great News! We saved a bunch of money by switching to KAS!

12.

13. It ain’t easy bein’ Green.

14.

15. Mmm, Mmm….Good!

16.

17. Long day? KAS can fix that.

18.

19. And yes, even Games

20. What did this get us? BD - Holdrege Submitted KAS 2000 1800 1600 1400 1200 1000 800 600 400 200 0 175% Increase! 2006 2007 2008

21. Our KAS System needed Kaizen

22. IT Solutions

23. KAS Database

24. Remove the Constraint and… BD - Holdrege Submitted KAS 4500 4000 3500 10 per emp 10 per emp Another 123% Increase! 3000 6 per emp 2500 4 per emp 2000 1500 2 per emp 1000 1 per emp 500 0 2006 2007 2008 2009 2010 Implementation Rate of all ideas has run 97-98% since 2009 2011

25. Recognition Program CI coordinator Team Leader KAS winner Manager BD Holdrege Kaizen reward program changes every year. 2010 (small prizes for # of Kaizens) 2011 (Big Prizes) TV,BBQ,Laptops 2012 (Cash rewards) $50 - $350 Receive a certificate of appreciation signed by Plant Manager and CI Leader Tip: Have Vision project every year on how to engage associates in Kaizen program

26. Holdrege FY12 Kaizen Program • 4 KAS • Reward Program (Direct deposit with next pay-check) • • • Monthly lottery (random) drawing of $50 Monthly Exceptional drawing of $350 Quarterly Safety Kaizen drawing of $350 • The announcement of the winner will be made during the next Monthly Business Communication meetings and also in our Ultra Fine Times Newspaper.

27. Exceptional Kaizen?

28. Kaizen as a Management Tool Plant Manager Leader Standard Work Activity Safety Quality Task incident reports on any new injury Perform BBS Observation for Team Member Change Control Monthly Weekly Daily As Needed Mon Tue Wed Thr Fri X X X review one CAPA implemented actions where implemented (when applicable) X X Attend a PVD Board Meeting X Morning Board Walk Walk one whole Value Stream 20 Keys Audit one Line (may piggyback w /staff) X X X X Productivity Ops Review Review TRS Process on one cell X X X X X CI Review X Inspire on KAS / SAR with team member X Review / Challenge Skills Matrix Review an implemented KAS/SAR with responsible employee on the floor Review Lean Blitz on floor with team Verify / Challenge WIP levels on in one cell Coach / Mentor a Subordinate through solving a problem Development Give positive feedback to at least one employee One on One with Managers X Kaizen X X X X X X X X

29. In Summary Ensure project completion and share results Encourage participation – be involved Focus on 1 Kaizen at a time Give feedback / communication Develop a system (dB) to keep track of progress Have Fun

The Value of Employee Engagement

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