KATA

© 2016 The Leadership Network®

© 2016 Jidoka®

01

Process Metrics vs Outcome MetricsManypeoplehavedifficultyunderstandingtherelationshipanddifferencesbetweenaProcessMetricandanOutcomeMetrics.Theconcepttheyfailtounderstandistwofold:

1. ProcessMetricsaremeasurementsinrealtime.Itishoweverpossibletoconsiderameasurementeitheratacertainpointintimepastthebeginningoftheprocessormaybeattheendoftheday.ProcessMetricsaremetricsthatyoucangather“inthemoment”• Examplearesuchaconstructionofarunchartinthepreviousslidesonlowest

repeatableprocesscycletimeorthevariationfromcycletocycle.• Anotherexampleisrework.Wecanmeasurethefirstpassyield(FPYforthedayat

anypointintheshiftandknowatwhatratewearehavingtorework

2. ProcessMetricsaffectormanytimesdeterminethevalueswegetasOutcomeMetrics.ManytimeswerefertotheProcessMetricasthe“lever”thatcontrolstheOutcomeMetric.• Example:AnOutcomeMetricforapotofboilingwaterisdeterminedbytheProcess

Metricofthestoveburnerelement.OutcomeMetric=TemperatureofWateris100oC

ProcessMetric =KnobSetat7ona10notchdial

ProcessCharacteristic =sizeofthepot;sizeoftheheatingelement; volumeofwater

KATA

© 2016 The Leadership Network®

© 2016 Jidoka®

02

Process Characteristic =Cold vs Hot

KATA

© 2016 The Leadership Network®

© 2016 Jidoka®

03

Current Condition Side of the Storyboard –Healthcare, Emergency Dept.

Achieveby:3July

ProcessCharacteristics• Capacityof215patientsin24hours;40%oftotalvolumeis1500-2300• 45beds,MedicalscreeningandTrauma• No.ofNurses=44total;16on0700-1500,10on1500-2300,18on2300-0700• Two15minbreaks,One30minlunch

ProcessMetrics• LabsTurnaroundtime(TAT):

• Bloodpanels=45min;Urinalysis=35min;Radiology=60min

OutcomeMetrics• PatientLengthofStay(LOS)tod/c=260min• PatientLengthofStay(LOS)toadmit=310min

EMSarriveswithpatient

TraumaorMedicalScreening?

MedicalScreeningExam-Physician

LabsorderbyPhysician

PhysicianDiagnosis &TreatmentbyNurse

Dischargedoradmitted

KATA

© 2016 The Leadership Network®

© 2016 Jidoka®

04

Target Condition Side of the Storyboard –Healthcare, Emergency Dept.

Achieveby:3July

ProcessCharacteristics• Capacityof215patientsin24hours,40%oftotalvolumeis1500-2300• 45beds,MedicalscreeningandTrauma• No.ofNurses=44total10on0700-1500,20on1500-2300,14on2300-0700• Two15minbreaks,One30minlunch

ProcessMetrics• LabsTurnaroundtime(TAT):

• Bloodpanels=30min;Urinalysis=25min;Radiology=20min

OutcomeMetrics• PatientLengthofStay(LOS)tod/c<220min• PatientLengthofStay(LOS)toadmit<260min

EMSarriveswithpatient

TraumaorMedicalScreening?

MedicalScreeningExam-Physician

LabsorderbyPhysician

PhysicianDiagnosis &TreatmentbyNurse

Dischargedoradmitted

KATA

© 2016 The Leadership Network®

© 2016 Jidoka®

05

TargetConditionAchieveby:06.10.2016

CurrentCondition

ProcessMetrics ProcessMetrics

OutcomeMetrics OutcomeMetrics

F/A-Pack

Mill8

Mill7

Mill6

Mill5

Mill4

Mill3

Mill2

Mill1

CNC2

CNC1

Shaper6

Shaper5

Shaper4

Shaper3

Shaper2

Shaper1

Hob18

Hob17

Hob16

Hob15

Hob14

Hob13

Hob12

Hob11

Hob10

Hob9

Hob8

Hob7

Hob6

Hob5

Hob4

Hob3

Hob2

Hob1

Hob0

Hob1

50

48

46

44

42

40

38

36

34

32

30

28

26

24

22

20

18

16

14

12

10

8

6

4

2

0

OTHERPROCESSMETRICS:

MillReliabilityis80%

OvertimeisduetomachinereliabilityatTurningMills1,7,&8

NOTESANDOBSERVATIONS

PROCESSCHARACTERISTICS:

Wehaveexcesscapacityandhighvariationinmachinecycle

withourHobMachines.Hob18cycletimeexceedsTaktTime

Wehaveexcesscapacityandhighvariationinmachinecycle

withourTurningMillMachines.

PPLH=27.5

Scrap=6.7%

OverTime=8%

FirstPassYield=93%

ExitCycleVar(Pack)=10s+/-12%

Hob18LowestRepeatable HiVar=+195%

LoVar=-24%=14seconds

TaktTime=12.3seconds

PlannedCycleTime=10.5Seconds

NumberofShifts=3

NumberofOperators=10

CURRENTCONDITIONSUMMARYSHEET

OutcomeMetrics(SeeCharts)

ProcessStability:

FirstPassYield> 95%MillReliability> 85%

PPLH> 37.5Scrap< 5%Overtime<10%

FocusProcess: Challenge: ItwouldbeColossal,ifby1.1.2017,theACMEmachiningcelloccupied50%lessfloorspace,operating2shiftswith50%ofthemachinery,sowecanachieve:50PPLH,< 3.5%Scrap,withNoOvertimeACMEMachiningCell

Obstacle

1

2

3

4

5

Workload on operators

Scrap

OBSTACLESPARKINGLOTHowwillyoumeasurethat?

Less number of Hobs

Less number of Turning Mills

TheLearnershould pointandtouch thestoryboardandreadfromit.Itislikehis/herhandhold onthebus