Frito Lay - Continuous Improvement
Summary
TLDRFred 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
- π Continuous Improvement is a core philosophy at Fred Delay, aimed at enhancing problem-solving and performance.
- π οΈ The company has integrated various improvement methodologies like Autonomous Maintenance, Lean Six Sigma, and Team Ford Building over the years.
- π£οΈ Feedback from the field indicated that the multitude of improvement tools and processes had become overly complex.
- π€ There was a realization that the focus might have shifted from solving problems to managing the complexity of the processes themselves.
- π₯ A team of field leaders developed a streamlined approach called the CI Performance Model to simplify and consolidate the improvement efforts.
- π‘οΈ The CI Performance Model amalgamates the best elements of existing tools, making them more accessible and less cumbersome.
- π‘ The new model emphasizes empowering frontline teams with problem-solving skills rather than overwhelming them with process.
- π The CI Performance Model is designed to make problem-solving more efficient, allowing those closest to the issues to address them directly.
- π§ If escalation is needed, the model ensures that resources are available to support the frontline teams in their problem-solving efforts.
- π 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
π 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.
Mindmap
Keywords
π‘Continuous Improvement
π‘Autonomous Maintenance
π‘Lean Six Sigma
π‘Team Ford Building
π‘Change Management
π‘Problem-Solving
π‘CI Performance Model
π‘Simplification
π‘Empowering People
π‘Nimble
π‘Competitive
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
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