Lean Champion Bootcamp V.: ESAB India, Chennai 19 - 30 July 2010

Lean Champion
Bootcamp V.
ESAB India, Chennai
19th 30th July
2010
Safety
SAFETY
COMES
FIRST !!!
I Could Have Saved A Life Today

I could have saved a life today, but I chose to look the other way.
It wasnt that I didnt care, I had the time, and I was there.
But I didnt want to seem a fool, or argue over a safety rule.
I knew hed done the job before, if I called it wrong, he might get sore.
The chances didnt seem that bad, Ive done the same, he knew I had.
So I shook my head and walked on by, he knew the risks as well as I.
He took the chance, I closed an eye, and with that act I let him die.
I could have save a life today, but I chose to look the other way.
Now every time I see his wife, Ill know I should have saved his life.
That guilt is something I must bear, but it isnt something you need to share.
If you see a risk that others take, that puts their health or life at stake.
The question asked, or thing you say, could help them live another day.
If you see a risk and walk away, then hope you never have to say,
I could have saved a life today, but I chose to look the other way.
Introductions / Creature Comforts

Toilets
Smoking
Refreshments
Fire
Mobile phones
Safety on the shop floor
Interactive Training Course
Ice Breaker..
The Team
Game
Introductions And Expectations
Verbally
Name
Site
Position
Responsibilities
Experience with Continuous Improvement
Questions / Expectations of Course
Course Objectives
To deliver a practical and detailed understanding of the Unipart Way philosophy,
principles, tools and techniques.
To gain a deep understanding of some of the core tools and techniques of the Unipart
Way through practical application.
To understand the importance and key elements of team working in a continuous
improvement culture.
Delegates understand how The Unipart Way supports and integrates lean principles into
their organisations overall business strategy.
Delegates leave with a plan for implementation of Lean at their site.
To support ESAB Indias lean activities by identifying, prioritising and implementing
further improvement opportunities and benefits that are sustainable.
Continue to develop a community of lean advocates.
Agenda - week 1
MON
TUE
WED
THU
FRI
SAT
19-Jul
20-Jul
21-Jul
22-Jul
23-Jul
24-Jul
08:00 Team exercise (visual mgmt) 08:00 Team Announcements

08:30 8 Step Strategy
08:00 Team Announcements
Facilitator feedback
09:30 Coffee
08:45 Factory presentations
09:45 MIFA
09:45
Facilitator Feedback
Brief - Presentation and
storyboard

08:45 5S
08:45
09:30 Coffee
09:00 Leading Change
10:15 Coffee
10:00 Coffee
09:45 Coach (hotel to plant)
10:00 Coffee
10:45 Presentation dry runs
11:45 Process mapping
10:15 Visual Management
11:15 Comm. Cell meetings
10:15 PDM
12:15 Lunch
12:15 Lunch
12:15 Lunch
10:45 SMED
11:30 High / low level MIFA
14:00 Opening speech - Hariharan
13:00 7 Wastes
11:45
Introductions
13:45 Insight Star (Video)
12:15 Lunch
Ice Breaker
14:30 One Point Lessons
Course Agenda
Team Working
MIFA Exercise
ESAB Way
Health and Safety

presentation
12:45
Lunch @ plant (breakout

rooms)
11:45 WPA
13:30
High / low level MIFA Contd
12:15 Lunch @ hotel
Process Mapping
14:45 Coffee
14:00 Plant tour
Insight Stars
14:00 Comm. Cell meetings
15:00 Comm. Cell
14:45 Data gathering:
Comm. Cell exercise (KPIs)
Project brief + issue data

packs
PDM exercise
High level MIFA
18:00 Coach (plant to hotel)

20:00 Dinner
KPI's
Future state maps
16:15 Introduction to Unipart
16:45 OCC / CPS
Construct comm. Cell
Benefits analysis
Team exercise (Visual mgmt) 18:00 Depart from Temple Bay

19:30 Dinner (Hariharan)
20:30 Dinner at City Hotel
15:00 Close
Finalise current state maps
16:30 Coffee
OCC Exercise
13:00 Present to ESAB India SMT
14:15 Process trials
16:00 Coffee
17:00 Need for Change
08:45 Presentation Preparation
Presentattion prep (photos

etc)
19:00 Reach Hotel & Fresh-up
19:30 Dinner (Mike Foster)
20:00 Dinner
Coffee Break @ Plant From 15:15 to 15:30 and the session will continue after the break
The agenda is subject to change at any time. Please

ALWAYS check with your facilitator
Agenda - week 2
The agenda is subject to change at any time. Please

ALWAYS check with your facilitator
Course Trainers
Sean Ferneyhough
UMEP Regional Manager
David Mead
UMEP Regional Manager
Course Support Team

Facilitator Team:
Chris Isherwood
Madhusudana
And
Team Facilitator
Andrs Talabr
Team Facilitator
Camilla Jarleskog
Team Facilitator
Simon Kennell
Syndicate Teams
SUNDAR
SUNDARLAKSHMANAN
LAKSHMANAN
RRVAITHAMANITHY
VAITHAMANITHY
CASE STUDY AREA

Extrusion
GANGULY
GANGULYAAKK
ABHAY
ABHAYDATTATRAYA
DATTATRAYABARIDE
BARIDE
RAJESH
RAJESHSURYBHANJI
SURYBHANJICHURAD
CHURAD
SUGENG
SUGENGRIYADI
RIYADI
EDDIE
EDDIEZHANG
ZHANG
ARUN
ARUNPRABHU
PRABHU
FACILITATOR
FACILITATOR
Andrs
AndrsTalabr
Talabr
Syndicate Teams
ANAND
ANANDTT
K.S.GANESH
K.S.GANESH
CASE STUDY AREA

Submerged Arc
welding
Flux plant
SUDIPTA
SUDIPTAGHOSH
GHOSH
PRABIR
PRABIRDAS
DAS
TAPAS
TAPASKUMAR
KUMARPATRA
PATRA
SSNEELAKANDAN
NEELAKANDANIYER
IYER
VISHWAS
VISHWASM.
M.KAMBLE
KAMBLE
YYUSUF
USUFSUPENDI
SUPENDI
FACILITATOR
FACILITATOR
Camilla
CamillaJarleskog
Jarleskog
Syndicate Teams
BISWADEEP
BISWADEEPBANERJEE
BANERJEE
GAUTAM
GAUTAMDHAR
DHAR
PARTHO
PARTHODEY
DEY
TAPAN
TAPANKUMAR
KUMARPAHARI
PAHARI
SANJIB
SANJIBDHARA
DHARA
SUBHRANGSHU
SUBHRANGSHUDAS
DAS
C.R.BALAJI
C.R.BALAJI
GGSSSRIRAM
SRIRAM
KAI
KAILI
LITAN
TAN
FACILITATOR
FACILITATOR
Simon
SimonKennell
Kennell
Team Awards
There will be three team awards. The three awards are:
1.Best Safety
2.Best Visual Management
3.Best Overall Team
Course Rules
This is a real opportunity to learn about The Unipart Way + Lean Manufacturing
All we ask is the following:
Set an excellent example of a champion that is committed to the successful implementation of

Lean Manufacturing.
Wear Team Colours with pride.
Wear all PPE where and when necessary.
Arrive on time for the bus if you are late the bus will go without you!!
- You will have to negotiate a time to rejoin the course and apologise to your team mates
your team will lose points
When in the factory arrive on timefor sessions, if late do not enter your facilitator will come
and find you.
- You will have to negotiate a time to rejoin the course and corrective action maybe taken!!
When on the shop floor please be courteous to the operators / foreman / management
- DO NOT STRAY ONTO THE LINES WITHOUT YOUR FACILITATOR!!
When in lectures no interruptions No mobile phones / pagers / Messages etc.
When in the hotel all team rooms must be locked and keys handed to reception by 22.00pm
Treat the hotel and the staff with respect and remember other guests are staying there as
Use the course as an opportunity to learn well!!

about the other factories and how they
plan to apply Lean Manufacturing.
Use the course as an opportunity to see how to effectively develop a successful

team.
Enjoy yourself and have fun!!
Lean Champion Accreditation Rules

All sections of the course are compulsory attendance.
Failure to attend any section will result in automatic failure of
the course.
If one day of the course has to be missed, then the whole
week has to be re-sat on the next available course (providing
space is available.)
For the exam, the pass mark is 70% (This equates to 30% of overall
mark)
If the candidate is a borderline pass/fail, they will be given an

oral examination by one of the Course Leadership Team.
Practical sessions are assessed through presentation of
activity boards. Candidates must reach a pass grade for the
board marking
Thought For The Day..

There Is Little Difference Between A Winner and A Loser
The winner thinks of reasons why he CAN do it.

The loser thinks of reasons why he CAN NOT do it.
This Small Difference Makes A Big Difference In Their Lives
Having A Short Mental Break

The Stretch Break
PLEASE
GIVE
MY
BRAIN
A
CHANCE
Final Course Presentation

1. Each team has 25 minutes for presentation and 5
minutes for questions
2. Each team should prepare the following:
a.
A full set of activity boards showing their activities over the two
weeks of the Lean Champion Boot camp course.
i. These boards are based on previously developed materials
ii. The boards should show any improvements and forecasted
benefits identified during the course
iii. A brief summary of ESAB Mor containing best practice
examples and priority areas for improvement.
b. Robust plans on how they are going to progress Lean in their

respective factories.
Team Working
WCM Instructor Programme
The Unipart Way
Team Working
Develop a team identify
Pick A leader
Define team roles
Have A Timekeeper
Carry out Briefing and
De-briefing sessions for syndicate work
Organize your room
Together
Everyone
Achieves
More
Team Exercise (1)

In your Teams please complete the following
Name your team and produce a logo
Bring your board to life!!
- use coloured pens / tape .etc
You have 30 minutes to complete this exercise
What is a Good Team?
Elements of a Successful Team
1.
2.
3.
4.
5.
6.
7.
Climate
Involvement
Leadership
Problem Solving
Decision Making
Communication
Conflict
Team Performance - Climate
Create an Atmosphere that is cooperative and supportive.

Clearly Defined set of Goals
An atmosphere free of fear, where everyone can offer ideas
without criticism.
Provide a comfortable room or setting where team members can
discuss, learn, and data gather.
Team Performance - Involvement
Everyone is involved and using their abilities.
No Rank Allowed, everyone is equal
Everyone is fully engaged
Team Performance - Leadership
Leadership can shift among team members to whomever has the

expertise for the particular task.
Democratic atmosphere where everyones ideas are sought and
utilized.
Team Leader for the day keeps the team focused and productive.
Team Performance - Decision Making
Attempt to make decisions by consensus. Assure that everyone

had their input and listened to the ideas and reactions of all.
All team members must support the team decision made, even
though they might not completely agree with the decision.
Team Performance - Communication
Keep Open lines of communication:
Good Listening skills are required

Always respond constructively
Provide all feedback in a positive manner
Let one person at a time talk so all can benefit from their information
Make Team Norms and stick to them
Team Performance - Conflict
Healthy conflict can spark a team to more creative thinking and

solutions.
Tuckmans Team Development Model
Dr Bruce Tuckman 1965
Team Development - Forming

High dependence on leader for guidance and direction.
Little agreement on team aims other than received from leader.
Individual roles and responsibilities are unclear.
Lots of questions about the team's purpose, objectives and external
relationships.
Processes are often ignored.
Members test tolerance of system and leader (team leaders beware!).
Leader directs.
Team Development - Storming

Decisions don't come easily within group.
Team members vie for position as they attempt to establish themselves.
The leader might receive challenges from team members (beware the sharks!).
Clarity of purpose increases but plenty of uncertainties persist.
Cliques and factions form and there may be power struggles.
The team needs to be focused on its goals to avoid becoming distracted by
relationships and emotional issues.
Compromises may be required to enable progress.
Team Development - Norming

Agreement and consensus forms among team.
Roles and responsibilities are clear and accepted.
Big decisions are made by group agreement.
Smaller decisions may be delegated to individuals or small teams within group.
Commitment and unity is strong.
The team discusses and develops its processes and working style.
There is general respect for the leader and some of leadership is more shared by
the team.
Leader facilitates and enables.
Team Development - Performing

The team is more strategically aware; the team knows clearly why it is doing
what it is doing.
The team has a shared vision.
There is a focus on achieving goals.
The team has a high degree of autonomy.
Disagreements occur but now they are resolved within the team positively and
necessary changes to processes and structure are made by the team.
Team members look after each other.
The team does not need to be instructed or assisted.
Team members seek personal and interpersonal development.
Leader delegates and oversees.
Team Development
Which stage will your team get to?
Engaging People in Team Working

Traditional Company
Lean Enterprise
What is the problem?
Result of someone
messing up
Deviation from standard
What is the cause?
Individual (5whos)
System (5 whys)
Who is responsible?
Person who makes

mistake
Management
What should the individual

who makes a mistake do?
Solve problem on own if

possible
Call attention to problem

for assistance and to avoid
the problem in the future
Assumptions about people
They will not accept the

blame unless forced to
They will feel empowered if

they get positive support
for solving problems
Problem-solving skill
Some have it, some dont
It can and must be taught
A Successful Teams Environment

ORGANISATION
ORGANISATION
PLANNING
PLANNING
Teamworking
Why are we interested in

Teamworking ?
The Unipart Way & Teamworking
LEAN
LEAN
LEAN
LE
AN
Unipart Way
focuses
TEAMS
on solving
Problems
Teamworking The Unipart Way

A competent and committed individual can make a significant
contribution to improving the business. However, when
individuals join together the potential is enormous:
The effect of the whole is greater than the sum of the
individual parts.
The Unipart Way emphasises the importance of teamworking
because;
A team can do more jobs an
individual cannot.
2 + 2 = 10
Team are more likely to produce

better results.
The overall time taken to identify, plan

and implement the required changes
successfully, will generally be less than
with the individual approach.
The changes required to improve

the business are more likely to be
accepted by the team involved and
the team is more likely to persuade
others to accept the changes.
Team building creates an environment

for personal development,
strengthening the organisation and
harnessing the individual potential for
further business
Teamwork is
Fun.
Team Exercise (2)

Red Team
Fire & Evacuation procedure hotel
Blue Team
Factory Health & Safety
Grey Team
Emergency Contact Numbers (Factory & General)
RULES: Cannot speak, use written words or numbers
Train other teams Tuesday 20th July, 8.00am (2 mins. max)

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Lean Champion

I Could Have Saved A Life Today

Introductions / Creature Comforts

Introductions And Expectations

08:00 Team exercise (visual mgmt) 08:00 Team Announcements

08:00 Team Announcements

08:45 Factory presentations

08:00 Team Announcements

08:00 Team Announcements

09:00 Leading Change

09:45 Coach (hotel to plant)

10:45 Presentation dry runs

11:45 Process mapping

10:15 Visual Management

11:15 Comm. Cell meetings

11:30 High / low level MIFA

14:00 Opening speech - Hariharan

13:45 Insight Star (Video)

14:30 One Point Lessons

Health and Safety

Lunch @ plant (breakout

High / low level MIFA Contd

12:15 Lunch @ hotel

13:00 Coach (hotel to plant)

13:00 Coach (hotel to plant)

14:00 Plant tour

14:00 Comm. Cell meetings

15:00 Comm. Cell

14:45 Data gathering:

Comm. Cell exercise (KPIs)

Project brief + issue data

High level MIFA

18:00 Coach (plant to hotel)

Future state maps

16:15 Introduction to Unipart

16:45 OCC / CPS

Construct comm. Cell

Team exercise (Visual mgmt) 18:00 Depart from Temple Bay

20:30 Dinner at City Hotel

17:00 Coach (plant to hotel)

Finalise current state maps

13:00 Present to ESAB India SMT

14:15 Process trials

17:00 Need for Change

08:45 Presentation Preparation

Presentattion prep (photos

19:00 Reach Hotel & Fresh-up

18:00 Coach (plant to hotel)

19:30 Dinner (Mike Foster)

The agenda is subject to change at any time. Please

The agenda is subject to change at any time. Please

Course Support Team

CASE STUDY AREA

CASE STUDY AREA

Set an excellent example of a champion that is committed to the successful implementation of

Wear Team Colours with pride.

Wear all PPE where and when necessary.

When in lectures no interruptions No mobile phones / pagers / Messages etc.