Gain an overview of three essential Continuous Improvement (CI) programs, popular use cases and implementation tactics. Learn how to identify and act upon opportunities for incremental improvement to minimize costs, reduce waste and streamline workflows, while also maintaining quality and high customer satisfaction. Watch the full presentation here: https://info.safetychain.com/three-key-methods-unlock-continuous-improvement

1. Beyond Compliance
Webinar & Podcast Series for Process Manufacturers
Three Key Methods to Unlock
Continuous Improvement Across Your Plant
Brandon Wright
Customer Success Coach
Eric Hansen
VP, Customer Solutions

2. // Meet Your Host
✔Improve Yield
✔Maximize Productivity
✔Ensure Compliance
Plant Management Platform
hello!

3. BEYOND COMPLIANCE
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.
Eric Hansen
VP, Customer Success
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.
Today’s Speakers

4. BEYOND COMPLIANCE
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)

5. BEYOND COMPLIANCE
There’s a lot in the CI toolbox
PDCA
Gemba
Walks
5 WHYS
Kata
Coaching
Muri,
Mura,
Muda
Continuous
Improvement Software
LEAN
Six
Sigma
TQM
ISO 9000
Theory of
Constraints
AGILE
Lean
Start
up
Just in
Time
Jidoka
Continuous Flow
Takt Time
Pull System
Heijunka
KAIZE
N
Growth Hacking
Lean 6
Sigma
8 Wastes
DMAIC
Daily
Huddles
Standard Work
Catchball
Hoshin
Kanri
Kanban Boards
Value Stream
Maps
Kanban
boards
Value
Stream
Map
8 Wastes

6. BEYOND COMPLIANCE
“
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, blind spots, periodic review
The best indicator of success in any venture is to have a
process and to manage that process.
Brandon Wright

7. BEYOND COMPLIANCE
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…

8. Using CMM, what best describes your
facility?

9. BEYOND COMPLIANCE
This is the way… or one way
Step 1
Document the current state,
and define ideal future state
Step 5
Update metrics, monitor
performance, report results
Step 2
Root cause analysis,
solution testing & selection
Step 4
Monitor, iterate,
finalize, formalize
Step 3
Implement solution
Process
Improvement
Model

10. BEYOND COMPLIANCE
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

11. BEYOND COMPLIANCE
Story Time: Theory of Constraints

12. BEYOND COMPLIANCE
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

13. BEYOND COMPLIANCE
Story Time: The Rafter Perspective

14. How many CI projects has your facility
completed in the last year?

15. BEYOND COMPLIANCE
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

16. BEYOND COMPLIANCE
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

17. BEYOND COMPLIANCE
Getting it to stick
Educate and
involve
employees
from the
beginning
Be present
beyond the
project,
check in on
the changes
Update the
metrics…
and inspect
what you
expect (check the metrics!)

18. White Papers & Surveys
Webinars & Videos
Product & Partner Info
Solution Consultation
BEYOND COMPLIANCE
More Resources at www.safetychain.com