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IndiZEN 2014 – 5th National Convention on Operational Excellence

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Key highlights

59 Indian Companies (12 from Service industry) and 5 Overseas company who participated.

Around 180 participants

We gave Masaaki Imai award to Mr. Shyam and Mr. Vinay

Keynote speakers were as follows
a. Opening keynote speaker: Mr.Shyam Talawadekar
b. Closing keynote speaker: Mr.Donald Dinero
c. Mr.Vinay Kaul
d. We also had guests from Govt of Gujarat, Timespro, etc.

We had 23 case studies from Manufacturing track and 9 case studies from Service track

The winner of case studies competition for Manufacturing were JK Files, Mahindra Two Wheeler & Alstom India and for Service track PSG Hospital was the winner

Participants visited Volkswagen, ARaymond, Suzlon, Tranter India, Sigma Electric (SEMCO) and L&G Spaces for Excellence inside tours

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Coaching Kata

A Kata is a structured routine that makes skills and mindset teachable. Coaching Kata is a set of teaching routines that helps you develop coaching skill. It is a coaching pattern that helps managers teach Improvement Kata thinking and acting.

2 types of Kata in Lean

1. Improvement Kata
2. Coaching Kata

Improvement kata is a four step routine that you practice daily in order to make striving and scientific working a habit while Coaching kata is vital to the process of embedding kata into an organizations culture. In order to apply either of the Kata, the learner should be provided coaching that details each of the patterns and provides feedback as necessary. The coaching kata can help an organization realize the possibilities inherent in other kata. Once you learn the Improvement Kata, the Coaching Kata develops your skill for teaching the systematic, scientific routine of the Improvement Kata through practice in daily work.

 Kaizen Kata

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Coaching Kata

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Who Should Carry Out Process Improvement?

Operator autonomy is a general misconception about the Kaizen way. It unfair to ask the operators to make parts, struggle with problems and make improvements.

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Leaders as Teachers

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Mentor and Mentee

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Mentor –Mentee Dialogue (Five Questions)

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Coaching KATA -Reflect on the Last Step Taken

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Mentor/ Mentee A3 Summary

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Coaching Kata Guidelines

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Coaching Kata Guidelines

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Coaching Kata Guidelines

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Coaching Kata Guidelines

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Coaching Kata Guidelines

  • The daily step taken towards the target condition are taken from the PDCA cycles & not from the list of Action Plan
  • In a PDCA cycle,  what we learn in one cycle often leads to another cycle
  • Meet at the focus process everyday
  • The PDCA record sheet is filled in by the mentee
  • Mentor asks the Five questions
  • Reflect on the last step

Knowledge Threshold

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See – Compare – Instruct Pattern

1. See    

Try to understand how the learner is thinking

(Coach is in observing, questioning, listening mode)

2. compare

Compare this to the desired pattern specified by the  Improvement kata

(Coach is in judging mode)

3. Instruct  

Introduce a course adjustment, if required

(Coach is in instructing or guiding mode)

Calibration

  • Why do we do this experiment?
  • Its not – “Lets see if this target condition will work”
  • Its about – “What we need to do to make it work”
  • Focus on seeing what does not go as planned
  • So we can learn, what we need to work on

Coaching Kata -Guidelines

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Coaching Kata Summary

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Coaching Kata Summary

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Learning

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The Process of Change

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Source –  Mike Rother and his book Toyota Kata


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IndiZEN 2014 – 5th National Convention on Operational Excellence

With India wanting to double the contribution of manufacturing from 12.5% to 25% of the GDP, Manufacturing Excellence or Operational Excellence has hit the spot light. The recently concluded Indizen 2014 was a national convention that saw more than 180+ Professionals, from 64 top India (also overseas) organizations come together at Pune. In its 5th edition, it is an event that celebrates Operational Excellence – bring case studies, best practice factory tours, tutorials and much more on one platform. It’s a platform to Learn, Share and Network on the theme of Operational Excellence.  

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IndiZEN 2014 concluded on Feb 12th evening and it received an impressive response from more than 180+ operational excellence thought and action leaders across the country and from overseas as well. This year the theme for the convention was Employee Excellence for Operational Excellence.

IndiZEN recognizes and awards top Operational Excellence efforts in India!

It gives an opportunity to Learn, Network and Share the work done by organizations in terms of implementation of Kaizen/Lean/Operational Excellence. This event brings an impressive opening & closing keynote speakers, face to face Q&As with India’s leading operational excellence experts, exciting and engaging knowledge sharing sessions, kaizen tours (visit world class plants – seeing is believing), and an intense case study competition. 

The event started with a great enlightening opening key note by Mr. Shyam Talawadekar, a corporate coach (on TOYOTA-Lean-Approach), Speaker and a Blogger who has authored over a dozen of books on Lean. His ‘World-of-Kaizen’, ‘Visual Management’, ‘Kaizen-Culture’ in Marathi have collectively sold over 20,000 copies. He has cross industry global experience as FAAAI-AOTS-expert in implementing Best Management Practices for sustained employee & business performance in LSIs like Bosch, Cumins, TATA, Eaton, Reliance, Mahindra (including Deming Award process at Nagpur), Crystal & Floreal group (HK), etc. 

Next opening key note address was delivered by Mr. Vinay Kaul. He is a Mechanical Engineer from IIT-Mumbai and P.G. from IIT-Mumbai in Machine Tool Technology.  With over 40 years of experience in the Industry, his insights on People Excellence for Operational Excellence were eye opening. He has been working as an advisor to several Indian Corporations from Military Aircrafts to Plastic Processing. His clients list includes TATA, Mahindra, Sulzer, Tranter India, etc. 

As always, we had huge demand for factory tours, a few of those who missed out on the tours (no space) were disappointed, however they soon found great value by joining and listening to National Case Study Competition and by attending knowledge sessions on Kaizen Teian, Kaizen Kata and Coaching Kata.

Track 1 – Three full buses were ready at 11.30 to take around 75 participants to ARaymond, Volkswagen and Suzlon on the first day.

This year there were 32 case studies (9 from Service sector and 23 from Manufacturing) which were presented in all and each one of them were of high quality and content, proving that operational excellence has deep roots across Indian Companies. 

The judges comprising of Mr. Narendra Lagoo, Mr. Achyut Vaidya and Mr. Vinay Kaul for Manufacturing sector case study competition and the judges for Service sector comprised of Mr. Donal Dinero and Mr. Shyam Talawadekar. The judges had a big challenge as they had to evaluate 32 case studies.

The audience broke into a loud applause as the four winners were announced, which were:

Manufacturing track

 1)      JK Files India Ltd

 2)      Alstom India Limited (Hydro Business)

 3)      Mahindra Two Wheelers Ltd.

 Service track

 1)      PSG Hospitals

Mr. Donal Dinero delivered the closing key note, where he spoke about TWI – Spanning The Functional Divide. On 12th, Mr. Dinero also conducted a full day session on ‘Training Within Industry’, and it was well attended. He spoke of Job Methods, Job Relations & Job Instructions and how it helps drive change.

During the concluding session of IndiZen 2014, Mr. Shyam Talawadekar and Mr. Vinay Kaul were awarded the ‘Masaaki Imai Citation’ for its noteworthy work in the domain of Operational Excellence. People waited with their breath held tight while the winners of the Case Study Competition were announced!

With 180+ participants from 64 companies (five from overseas), four track and five best class companies to tour, Indizen once again delivered value to all those present.

The objective behind Kaizen Institutes ‘IndiZen 2014’ as always has been to get Operational Excellence practitioners together to share, celebrate, network and learn. As India takes giant strides towards economic growth, becoming efficient in every economic sphere is critical for our future.

Brief overview of IndiZEN 2014

1.      64 organizations participated out of which 5 were from overseas

2.      180+ participants from various organizations and industries

3.      32 case studies for National Case Study competition

4.      5 host sites for Excellence Inside Tours

          a. ARaymond
          b. Suzlon
          c. Volkswagen
          d. Tranter India
          e. SEMCO

Apart from above mentioned 5 host companies participants also visited KAIZEN Institutes Lean & Green office.

 5.      Knowledge sessions on Kaizen Teian, Coaching Kata, Kaizen Kata, TWI, etc.

6.      IndiZEN 2014 had guests from India as well as overseas. To name the few IndiZEN 2014            had people like Mr. Donald Dinero, Mr. Shyam Talawadekar, Mr. Vinay Kaul,                                Dr. Nagendra Chowdary, Dr. J L Meena, etc.

7.      Judges for the case studies for Manufacturing track were Mr. Achyut Vaidya, Mr.                          Nagendra Lagoo, Mr. Vinay Kaul and for Service track were Mr. Donald Dinero and                      Mr. Shyam Talawadekar

8.      Masaaki Imai Citation was awarded to Mr. Shyam Talawadekar and Mr. Vinay Kaul

9.      Opening Keynote address was delivered by Mr. Shyam Talawadekar and Mr. Vinay Kaul               while the Closing Keynote address was delivered by Mr. Donald Dinero.

TO VIEW THE PHOTOS CLICK HERE


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Kaizen Story: The Crow and the Peacock

Once there was a crow. It had a burning desire of looking to be more Beautiful. The crow lived in a big Banyan tree, where a number of peacocks also lived. It saw the beautiful plumes of the peacocks and cherished a desire to look like one of them. It often cursed itself for being ugly. It scorned the whole crow community being black and ugly. It had an ambition to improve like a peacock so that the people may praise it.

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In order to fulfill its ambition, it thought how to break away with the crow community. After deep thinking it deceived upon an ambitious plan. It decided to collect dropped off feathers of the peacocks and fix them up into its own, so that it may look beautiful like peacock. The poor crow never thought that only fixing of the feathers could not make it a peacock. There are many other things such as color, size, and crest, which are the essentials of a peacock. After putting on the feathers of the peacock, the crow considered itself to be a peacock. It was beside itself with joy. It decided to go and live with the peacocks. It took a long flight and reached the place where some peacocks were walking around. It walked up and down among the peacocks. The peacocks saw this strange bird with surprise. It looked half crow and half peacock.

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The peacocks are known for their self-pride. They could not tolerate a crow posing to be a peacock. They could not break the presence of an imposter among themselves. At once they pounced upon the crow and broke away some of its artificial feathers. The crow was able to save its life with great difficulty. It flew at full speed for its life. The crow took a long flight and reached a place where some crows were perching. It began to move about proudly among the crows. The crows took it to be a different bird, resembling a peacock. They could not brook the presence of a peacock among themselves; they attacked it, pecking it hard with their beaks.

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Again the crow had to fly away for its life. It was pained at heart and flew to a lonely tree in the jungle. It did not know what to do. It though, it had tried to improve itself by fixing peacocks’ feathers into its own, but they could not make it peacock. It was no accommodated by the peacocks rather it was attacked for being a imposter. Not only this had even its own brethren- the crows disowned it. It was at a loss to know what to do now. At last it tore off all of its peacock feathers and became a crow again. It was only then that the crows owned it as one of them and accommodated it among themselves. The foolish crow had a bitter experience. It learnt a lesson for life. Do not adopt unnatural and unfair methods for self-improvement and do not try to copy out others.

 Moral of this story:

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  • It is not a story just to read and enjoy. It teaches us an important lesson that we should not try to improve ourselves only by imitating others but through hard work and sincere efforts.
  • We must not forego the moral ideals for attaining something.
  • The improper methods adopted stand in the way of desired achievements. Such methods are sure to affect the desired results. Even if we achieve something through such improper means, our achievement is not permanent. It is sure to be short lived.
  • You must avoid copying and cheating even in your examinations, because it is not a proper means.


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Kaizen Story: The boy who learned to swim

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A little boy once wanted to learn to swim. His parents took him to the local swimming pool and enrolled him with an instructor. After a few weeks, he had learned the basics of swimming and could perform a few strokes, travelling a few feet before stopping. His parents cheered and clapped. But the boy thought that he could still do better. So he kept going to swimming classes and after a few more weeks, he was able to swim across the little pool that he was learning in. His parents cheered and clapped. But the boy thought that he could still do better. He kept training and after a few more months he was able to swim an entire length of the main pool. His parents cheered and clapped.

But the boy thought that he could still do better. He kept training and was eventually able to turn and swim back the other way. After a few more months, he was able to complete a few laps of the pool in one effort. His parents cheered and clapped. But the boy thought that he could still do better. He started to enter swimming competitions and eventually won his first race. His parents cheered and clapped. But the boy thought that he could still do better. He went to the ocean and swam from the beach to a pier a few hundred meters away. His parents cheered and clapped.

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But the boy thought that he could still do better. He entered an ocean race that was a couple of kilometers in length and won at the first attempt. His parents cheered and clapped. But the boy thought that he could still do better. So he stood on the beach and looked out over the ocean, out to the horizon beyond. He wondered what the limits were on what he could achieve and whether he had reached them yet. And he aspired to something greater and set about planning how to achieve it.

Moral Of the Story:

We’re all that little boy. We all have some basic skills at something. Let’s not stop there. Let’s go from basic skills to competent. From competent to good! From good to great!

From great to expert! From expert to world-class! Look out to the horizon, dream big dreams and find a way to be magnificent

Acknowledgement: story taken from http://www.betterlifecoachingblog.com


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Kaizen story: Five Guardians

 

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Once a village had been  threatened by frequent bandit attacks for many years. Their approach to the governor was not much successful. Finally   the village head decided to call upon the “Five Guardians” who were notorious for their courageous fight against bandits. Further they also trained the villagers to defend themselves against any future attacks. They charged a hefty fee for their service. The next attack of the bandits towards the village was a real shocking for them to face the tough five guardians. With heavy loss, the bandits retreated with fear. Then it was the time for the Five Guardians to follow up the bandits and killed everyone. They also rescued the girls taken by the bandits from the village. The villagers received them with warm greetings.

Next, it was their turn to train up the village. But once they train up they have to leave the village as agreed. The best food, best wine & most beautiful girls from the village tempted the wanderers to settle down in the village. So they decided to make an offer to the villagers in waiving their fee for settling down. So the guardians settled in the village by marrying their daughters. They also learned farming for their survival. But the guardians were not interested in training up the villagers, because they felt that once they train the villagers fully they lose their importance.

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The villagers were also not interested in learning the defense believing the guardians were there to protect them. Years passed by and the villagers did not learn the warfare in spite of reminiscence by the village head. Instead the villagers considered his words as a nuisance until his death. The village was in peace until the guardians lasted.

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One day, a cloud of dust was steadily approaching the village; soon it turned into bandits who were rushing for attacking. Then the villagers without the guardians could only run for their lives.

Moral of the story:

•Never stop learning

Be honest for the customers who pay

Listen to the leaders

•Create leaders for tomorrow

Leaders are fallible; hence leadership has to be collective and pervasive