Frito Lay - Continuous Improvement

Summary

Fred Delay's company has been perfecting its continuous improvement processes for 20 years, incorporating autonomous maintenance, lean Six Sigma, and Team Ford methodologies. However, with the increasing complexity of these processes, they recognized the need for simplification. In response, they've developed the CI performance model, a streamlined approach that combines the best of their tools, empowering frontline teams to solve problems efficiently without being overwhelmed by processes. This new model aims to make the company more agile and competitive, leveraging employee knowledge to drive success.

Takeaways

• 🔄 Continuous Improvement is a core philosophy at Fred Delay, aimed at enhancing problem-solving and performance.
• 🛠️ The company has integrated various improvement methodologies like Autonomous Maintenance, Lean Six Sigma, and Team Ford Building over the years.
• 🗣️ Feedback from the field indicated that the multitude of improvement tools and processes had become overly complex.
• 🤔 There was a realization that the focus might have shifted from solving problems to managing the complexity of the processes themselves.
• 👥 A team of field leaders developed a streamlined approach called the CI Performance Model to simplify and consolidate the improvement efforts.
• 🛡️ The CI Performance Model amalgamates the best elements of existing tools, making them more accessible and less cumbersome.
• 💡 The new model emphasizes empowering frontline teams with problem-solving skills rather than overwhelming them with process.
• 📈 The CI Performance Model is designed to make problem-solving more efficient, allowing those closest to the issues to address them directly.
• 🔧 If escalation is needed, the model ensures that resources are available to support the frontline teams in their problem-solving efforts.
• 📈 The company plans to roll out the CI Performance Model across all teams, aiming to make the organization more agile and competitive.

Q & A

What is the main focus of Fred Delay's continuous improvement processes?

Fred Delay's continuous improvement processes focus on addressing and eliminating problems, enhancing performance, and adapting to a changing marketplace.

How long has Fred Delay been using continuous improvement processes?

Fred Delay has been using continuous improvement processes for 20 years.

What additional processes have been integrated into Fred Delay's operations?

Fred Delay has integrated autonomous maintenance, lean Six Sigma, and Team Ford building into their operations.

Why did Fred Delay's teams feel overwhelmed?

The teams felt overwhelmed because they had to manage multiple problem-solving processes, systems of escalation, and attend numerous meetings for each tool.

What was the feedback from the front lines regarding the improvement processes?

The feedback was that the teams had become too focused on the process of problem-solving rather than actually finding solutions.

What is the Design Approach developed by the team of field leaders?

The Design Approach is a process that leverages the best elements of their tools and simplifies them for easier use, aiming to enable teams with problem-solving skills without being bogged down by complex processes.

What is the CI performance model and how does it work?

The CI performance model is a streamlined process that combines the best of continuous improvement, autonomous maintenance, lean Six Sigma, and team forward, allowing those who understand the problem to solve it, with escalation resources available if needed.

How does the CI performance model empower the front-line workers?

The CI performance model empowers front-line workers by trusting and honoring their problem-solving skills and knowledge, giving them less to juggle and more focus on finding solutions.

What is the expected outcome of rolling out the CI performance model?

The expected outcome is to simplify processes, increase the ability of teams to solve problems, and leverage the knowledge of the people to implement a model that drives success.

How does Fred Delay plan to engage its front-line workers with the new CI performance model?

Fred Delay plans to engage its front-line workers by rolling out the CI performance model across all teams, providing new skills, and helping the entire company become more nimble and competitive.

What is the ultimate goal of the new approach mentioned in the script?

The ultimate goal of the new approach is to honor the past while embracing the future, ensuring the company remains successful by simplifying processes and empowering problem-solving at all levels.

Outlines

00:00

🔄 Continuous Improvement at Fred Delay

Fred Delay has been committed to continuous improvement for 20 years, focusing on addressing and eliminating problems and enhancing performance. They have integrated various improvement processes such as autonomous maintenance, lean Six Sigma, and Team Ford to enhance performance, consistency, and team impact. However, the complexity of managing these processes has led to an overwhelming number of meetings and a potential shift in focus from problem-solving to process management. Feedback from the frontlines has indicated that the improvement processes might be too complicated, prompting a need for simplification.

Keywords

💡Continuous Improvement

Continuous Improvement refers to the ongoing effort to enhance processes, products, or services by identifying and eliminating problems and inefficiencies. In the video, it is the foundational philosophy that has driven the company's operations for 20 years. It is about constantly measuring, evaluating, and improving how work is done, which is central to the company's approach to business and is exemplified by the various improvement processes they have implemented over time.

💡Autonomous Maintenance

Autonomous Maintenance is a concept where equipment is designed to be self-sustaining, requiring minimal human intervention for upkeep. In the context of the video, it is one of the improvement processes that the company has adopted to maintain complex, increasingly automated equipment. This approach is aimed at reducing downtime and ensuring operational efficiency.

💡Lean Six Sigma

Lean Six Sigma is a methodology that combines Lean manufacturing and Six Sigma to improve quality and efficiency by eliminating waste and reducing variability. The video mentions it as a process that the company has implemented to improve consistency in their products and streamline their workflow. It is a part of their broader continuous improvement strategy.

💡Team Ford Building

Team Ford Building, as mentioned in the video, is an approach to creating high-impact teams that focus on improving performance on the factory floor. It is about empowering teams to work together to solve problems and enhance productivity. This concept is integral to the company's strategy to improve overall performance and is a testament to their commitment to leveraging team dynamics for better results.

💡Change Management

Change Management is the process of preparing, supporting, and helping individuals and organizations to cope with change. In the video, it is highlighted as a necessity due to the constant changes in the marketplace, competitors, technologies, and processes. The company acknowledges the need to adapt and manage change effectively to stay competitive.

💡Problem-Solving

Problem-solving is the process of identifying, analyzing, and solving problems. The video script emphasizes the need to shift focus from the process of problem-solving to actually reaching solutions. It is a critical aspect of the company's continuous improvement efforts, where they aim to simplify the approach to ensure that teams can quickly and effectively address issues.

💡CI Performance Model

CI Performance Model is a new process developed by the company to streamline their improvement efforts. It combines the best elements of their existing tools like Continuous Improvement, Autonomous Maintenance, Lean Six Sigma, and Team Ford Building into a simpler, more efficient process. The model is designed to empower front-line workers to solve problems with the support of available resources if needed, as mentioned in the script.

💡Simplification

Simplification is the act of making something easier to understand or use by making it less complex. In the video, simplification is a key goal of the CI Performance Model. The company aims to reduce the complexity of their improvement processes to empower employees and drive the company forward more effectively.

💡Empowering People

Empowering people refers to giving individuals the authority and responsibility to make decisions and take action. The video discusses the importance of trusting and honoring the knowledge of the people who run the business every day. By simplifying processes and providing problem-solving skills, the company seeks to empower its teams to be more effective and agile.

💡Nimble

Nimble refers to the ability to move quickly and easily or to adapt to changes quickly. In the context of the video, the company aims to become more nimble by implementing the CI Performance Model. This agility is crucial for staying competitive in a rapidly changing market and for effectively addressing challenges as they arise.

💡Competitive

Competitive in the video refers to the company's desire to be in a strong position relative to its rivals in the market. By simplifying processes and empowering teams, the company aims to enhance its competitiveness. Being competitive is about not only maintaining market position but also about innovating and improving to stay ahead.

Highlights

Fred Delay is committed to continuous improvement, addressing and eliminating problems, and enhancing performance.

The company has a 20-year history of using continuous improvement processes to achieve great results.

Continuous improvement involves constant measurement, evaluation, and enhancement of work processes.

Fred Delay listens to its employees and implements changes if they can lead to improvements.

The company has introduced autonomous maintenance to handle complex, automated equipment.

Lean Six Sigma has been adopted to improve product consistency and streamline workflows.

Team Ford building focuses on creating high-impact teams to enhance floor performance.

The company must adapt to a changing marketplace, competitors, technologies, and processes.

Each improvement tool requires a different problem-solving process and system of escalation.

Feedback from the front lines indicates that the improvement processes have become too complicated.

Field leaders have developed a new process for leading improvement efforts, called the design approach.

The design approach aims to simplify problem-solving by leveraging the best elements of existing tools.

The new process is intended to empower teams with problem-solving skills rather than overwhelming them with complex processes.

The CI performance model combines the best of continuous improvement, autonomous maintenance, lean Six Sigma, and team forward into one streamlined process.

The CI performance model allows those who understand the problem to solve it, with escalation resources available if needed.

The company plans to roll out the CI performance model to all teams, engaging the front line with new skills.

The new approach will make the company more nimble and competitive, reducing the burden on employees.

The company seeks support and leadership to implement these changes and simplify processes at sites.

The new approach will honor the company's past and embrace its future, ensuring continued success.

Transcripts

[Music]

at Fred delay we're always looking to

improve the way we do things whether

it's addressing and eliminating problems

when they occur or taking our already

great performance and making it even

better for 20 years we've used

continuous Improvement processes to

deliver great results of course

continuous Improvement means we're

always measuring evaluating and

improving how we work we're always

listening to our people and if we we

find something that can make us better

we make changes but what if our

Improvement processes themselves are

becoming too complicated our foundation

has been continuous Improvement

improving performance each and every

day then we added autonomous

maintenance how we maintain complex

increasingly automated

equipment next came lean Six Sigma

improving consistency in our products

and streamlining our

workflow then Team Ford building high

impact teams to improve floor

[Music]

performance and of course

change constantly adapting to a changing

Marketplace competitors Technologies and

processes

that's a lot to

juggle each of these requires a

different problem solving process a

different system of escalation and each

requires a lot of meetings a lot of

meetings a lot of meetings the pace

amount and complexity of change prompted

our teams to voice this challenge with

all these tools have we become too

focused on the process of problem

solving instead of actually getting to

the solutions feedback from the front

lines to our headquarters team was a

unanimous yes in the spirit of

continuously improving the way we do

things a team of field leaders have

developed a process for leading our

Improvement efforts the design approach

leverages the best elements of our tools

and makes them easier to work with we

want to enable our teams with problem

solving skills versus bogging them down

in complex processes after all who

really understands our problems better

than the people who run our business

every day we need to trust that we need

to honor that are problem solving tools

and processes necessary of course so

what we're doing is taking the best of

continuous Improvement autonomous

maintenance lean Six Sigma team forward

and combining them into one simple

process that we call the CI performance

model it allows people who understand

the problem to solve the problem and if

it requires escalation those resources

are still available it's streamlining

the entire improvement process for our

front lines it's focusing on Simplicity

to drive us forward it's empowering

people instead of being overwhelmed by

process over the coming months we will

be rolling out CI performance model to

all of our teams across the country

we'll be engaging our front line with

new skills we'll be helping the entire

company be more Nimble and more

competitive giving everyone less to

juggle as you know we've come a long way

so we're asking for your support and

your leadership to make these important

changes a reality together we will

simplify the processes at our sites we

will increase the ability of our teams

to solve problems and we will leverage

the knowledge of our people to implement

a model that drives our success this new

approach will ensure we honor our past

and embrace our

[Music]

future