Manufacturers Turning Challenges into Opportunities...Sam Wagner SCI LLC –SCIence of Continuous Improvement & Training COVID-19 Webinar Series, Session #7 Today’s Presenter: Sam

This webinar series is being presented by:

CMMA, MPMA, TSMA, & Enterprise Mn

With Industry Partners:

AMFA, LAMA, Hwy 2 West, Manufacturers Alliance, and

Minnesota State Advanced Manufacturing Center of Excellence

Session 7:

Manufacturers Turning Challenges into Opportunities

Thank you, Sponsors

Thank you, Sponsors

THANK YOU 2020 MPMA Sponsors

THANK YOU 2020 MPMA Sponsors

• Plan your back-ups and partnerships!• Talk with your competitors/peers• Find or offer resources at Medical Alley or • Mn Chamber’s Grow Minnesota Initiative• MPMA is launching a Resource Exchange this

week

General Updates

• Legislation being reviewed for :• Protection for COVID-19 personnel exposure • Protection for Defective essential products • Senate “COVID Relief” tax bill with Section 179

conformity and statewide property tax delay• DLI has put out “back to work” guidance• SBA putting out more PPP forgiveness guidance

Legislative Updates

General Information

• For webinar recordings, Power Points and other COVID-19 updates, go to • MPMA’s COVID-19 resource page• TSMA’s https://www.tsma.org/covid-19

Manufacturers Turning Challenges into Opportunities

Sponsored by:

Facilitated by:

Sam WagnerSCI LLC – SCIence of Continuous Improvement & Training

COVID-19 Webinar Series, Session #7

Today’s Presenter: Sam Wagner• Over 30 years in manufacturing

• Certified Lean Leader

• Certified Trainer• Training Within Industry (TWI)

• Job Instruction

• Job Methods

• Toyota Kata• Coaching Kata

• Visual Workplace

• Mistake-proofing

• Setup Reduction

• Job Relations

• Job Safety

• Improvement Kata

[email protected]

320-815-9896

Agenda

Business Opportunities and Process Improvements born out of necessity due to COVID-19Improve

How these improvements relate to Toyota Kata principlesLearn

“New norms” that manufacturers should be prepared for going forwardPrepare

Challenges

Opportunities

New Customer Needs – Masks

N-95 equivalent

New Product?New Product? Community Service

Cubicles → Sneeze shields

Isolation Systems

Chandler Industries

Montevideo

Long Prairie

Bethel

Ventilator components

Alexandria Industries

Process Improvement

• Problem: Sawing/Punching cell currently takes two people to operate in close proximity

• Approach: Use Job Methods from Training Within Industry to analyze the process and identify ideas to do this with one person without losing too much productivity

Using Job MethodsJob Methods:

A practical plan to help you produce greater quantities of quality products in less timeby making the best use of the manpower,

machines, and materials now available

Why?

What?

Where?

When?

Who?

How?

Eliminate

Combine

Rearrange

Simplify

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Process Improvement

• Problem: Sawing/Punching cell currently takes two people to operate in close proximity

• Approach: Use Job Methods from Training Within Industry to analyze the process and identify ideas to do this with one person without losing too much productivity

• Results: Sawing/Punching cell now takes one person to operate… with better ergonomics & quality and 15% improved productivity

Agenda

Business Opportunities and Process Improvements born out of necessity due to COVID-19Improve

How these improvements relate to Toyota Kata principlesLearn

“New norms” that manufacturers should be prepared for going forwardPrepare

Challenges

Opportunities

The pattern we practice to learn to navigate in unknown territory

Scientific Thinking pattern to achieve a goal we don’t know how to reach

The Coach helps guide us in using the pattern

Moving through the “Grey Zone”

Obstacles

Unclear Territory

KNOWLEDGETHRESHOLD

PREDICTABLE UNPREDICTABLE = GREY ZONE = LEARNING

Next Target

Condition

No plan will cover everything, and that is OK

Agenda

Business Opportunities and Process Improvements born out of necessity due to COVID-19Improve

How these improvements relate to Toyota Kata principlesLearn

“New norms” that manufacturers should be prepared for going forwardPrepare

Challenges

Opportunities

New Norms???

More Remote Work

Cleanliness, PPE,

Social distancing

Flexibility, Adaptability, Responsiveness

Employee motivation data on Working Remotely

What matters? Choice & Kata

Ref: Harvard Business Review

Demand for rural homes shows ‘profound, psychological change’ due to coronavirus, Redfin CEO saysPUBLISHED FRI, APR 17 2020 5:38 PM EDT

• The CEO of real estate brokerage Redfin said Friday that demand for homes has

shifted to rural areas as people react to the coronavirus pandemic and look to

move out of dense urban areas.

• “We have seen that people are more interested in that house at the foot of the

mountains by the lake,” Glenn Kelman said on CNBC’s “Closing Bell.” “Rural

demand is much stronger right now than urban demand, and that’s a flip from

where it’s been for the longest time, where everybody wanted to live in the city.

We’ll see how it comes back, but there seems to be a profound, psychological

change among consumers who are looking for houses.”

Possible Benefits of Adapting to COVID-19

• More remote work• Less facility space

requirements per employee (and related overhead)

• Wider recruitment area

• Less traffic

• Potential for higher employee motivation

• Flexibility, Adaptability, Responsiveness• Stronger

organization, better able to respond to dynamic conditions

• Cleanliness, PPE, Social distancing• Healthier workplace;

less overall absenteeism

• Potential for better physical organization

Agenda

Business Opportunities and Process Improvements born out of necessity due to COVID-19Improve

How these improvements relate to Toyota Kata principlesLearn

“New norms” that manufacturers should be prepared for going forwardPrepare

Challenges

Opportunities

Manufacturers Turning Challenges into Opportunities

Sponsored by:

Facilitated by:

Sam WagnerSCI LLC – SCIence of Continuous Improvement & Training

[email protected]

320-815-9896

COVID-19 Webinar Series, Session #7