Rapid Action tools and discipline are easily integrated into existing Lean Six SIgma Deployments at the projects, roles and training interface.
Most importantly, Rapid Action materials are harmonized with Lean Six Sigma terms and concepts.
Rapid Action Integration into Lean Six Sigma Projects
Rapid Action applies across the full spectrum of Lean Six Sigma projects. The result: Better utilization of tools and methods already in place and better discipline on non-traditional projects such as Quick Wins and Solution Replication.
"Secret Reagent Man" Rapid Action Team
A major Fertilizer Processing Company added Rapid Action Tools to its Lean Six Sigma Deployment to leverage the talents of a small cadre of Black Belts with a large workforce of frontline process operators. Read below for one example and the surprising and profitable result of combining Black Belt analytical skill with frontline know-how and ingenuity.
DMAIC Project Charter:
Reduce the cost and consumption levels of reagents used in fertilizer processing with no loss in product quality or yield.
Rapid Action Tools Application:
- Black Belt completed DMA steps to confirm baseline costs, usage and product yield.
- Black Belt identified multiple problem causes, most related to production practices.
- Rapid Action Team of shift supervisors and operators assembled; briefed on the problem and causes; engaged in brainstorming, testing and implementing solutions.
Solutions Implemented:
- Steam cleaned reagent lines to improve flow; wrote new SOP to standardize.
- Improved mixing equipment performance by patching leaks; standardized maintenance procedure across shifts.
- Trained operators to use refract-o-meter to test for proper mixing.
60-Day Results:
- Ten solutions tested and fully implemented over 58 days.
- 27 additional actions recommended to Plant Management for future team assignment.
- Total reduction of $2.2 million in reagent spending on annualized basis.
- Total gain in yield of finished product equal to $2.3 million per year.
Master Black Belt
"Kaizanimals" Rapid Action Teams
A Bio-Pharma Operation integrated Rapid Action Tools into its Kaizen Event process for streamlining production processes to ensure ownership and follow-through on implementation of lean process solutions. Read below for one example of the power when Lean Principles and Strategies are combined with Rapid Action Tools for fast and effective implementation of process changes.
Kaizen Project Charter:
Increase through-put and improve yield on the Fermentation Stage of the product production process.
Rapid Action Tools Application:
- Value Stream Map and Lean Process Analysis Completed in Kaizen Event.
- Rapid Action Tools used in a large-group setting (30 people) to brainstorm, sort and prioritize solutions based on Lean Analysis.
- Three Rapid Action Sub-Teams launched focused on Implementation of 5S Discipline, Smooth Flow and Standardization and Error Proofing.
Solutions Implemented:
- Designed and installed new spool pieces to reduce set-up times and opportunities for error.
- Implemented a Kanban system for all supplies and raw materials.
- Developed a staging and delivery system of equipment to the fermentation unit removing over 2 miles of transportation time per product
60-Day Results:
- More than 35 solutions implemented in 64 days.
- Through-put doubled in less than 60 days.
- Product potency improved by 50%.
- Product losses reduced by 80%
- Total gains from increased through-put, potency and reduced losses more than $2.25 million annualized.
Fermentation Director
"Perfect Orders" Rapid Action Team
A Fortune 500 Business Services Company added Rapid Action Teams to its Lean Six Sigma Deployment as the standard method for capturing "Quick Win" improvement opportunities not requiring "deep-dive" DMAIC analysis. Read below for a classic example of a Green Belt leading a Rapid Action Project from launch to results in 60-days.
Quick Win Project Charter:
Improve accuracy of incoming sales orders in order to eliminate rework, improve response times to customers and reduce staff frustration in the order Entry Department.
Rapid Action Tools Application:
- Using Rapid Action Prelaunch Planner, Green Belt worked with Order Entry Manager to craft Rapid Action Team Charter.
- Green Belt assumed Rapid Action Team Leader role and launched team of customer service reps in four-hour Fast-Start Meeting.
- Team brainstormed, prioritized and assigned potential solutions for testing to each team member.
- Through short weekly Action Meetings and individual assignments, the team implemented five solutions over 65 days.
Solutions Implemented:
- Developed standard text for all order form fields.
- Established a clear and simple escalation process to quickly resolve problem orders.
- Created automated error detection and correction tools within order forms.
- Deployed training toolkits to all sales offices to improve use of standard order entry practices.
60-Day Results:
- Elimination of over 18,000 telephone calls per year to resolve sales order issues.
- 40% reduction on average in cycle-time required to resolve sales order problems.
- Reduction in external customer and sales rep telephones calls to inquire about order status.
- Improvement in orders "right the first time" vs. starting baseline from 50% to over 90%.
Green Belt Rapid Action Team Leader
"Right the First Time" Rapid Action Team
A nation-wide Appliance Repair Services Firm was looking to quickly standardized operational excellence best practices across its field offices. Rapid Action was selected as the method of choice and was deployed to successfully turnaround profitability and customer satisfaction problems across 50 locations in just over six months.
Quick Win Project Charter:
Reduce the number of repeat repair calls by service technicians by standardizing best practices across 50 field offices.
Rapid Action Tools Application:
- 1. Quick Win Rapid Action Team launched in one Branch location to test for replicable solutions.
- 2. Team of Service Technicians, Parts Clerks and Supervisor supported by Black Belt Coach complete 60-day Rapid Action Project and implement 10 solutions for reducing repeat service calls.
- 3. Solutions tested within Branch to validate results.
- 4. Solution Replication Campaign deployed to spread solutions across all Branch locations.
Solutions Implemented:
- Reorganization of Parts Stock in Service Trucks using 5S techniques to improve ease of access and accuracy.
- Analysis of parts usage trends to improve stocking of high usage parts.
- Institution of more disciplined call-first program to reduce "not home" occurrences.
60-Day Results:
- Solutions from initial Rapid Action Team reduced repeat repair calls for their Branch by 26% and generated annualized cost savings in reduced parts usage and overtime in excess of $40,000 per year.
- Deployment of Rapid Action Teams across all 50 Branches engaged more than 350 employees on 60-day solution replication projects all with completion timeframes of 60 days or less.
- Localization of global solutions by these teams produced annual cost savings of more than $2.5 million in just over six months.
Lean Six Sigma Deployment Leader
Integration into Lean Six Sigma Roles and Training
Rapid Action improves productivity at all Belt levels and with non-Belts as well. The just-in-time action learning design makes for easy application and participation by employees and leaders on the front lines.
Dave Galloway, Deployment Leader, NewPage Corporation
