This is one of the Factory Basics 101 Series courses, that has been developed to guide you in the process of implementing high performance teams, in a factory environment, as well as in administrative or service oriented work environments.
This 101 Series course has been developed using simple terminology that can be understood by someone looking into implementing high performance teams for the first time. It will also be useful for someone that is already running high performance teams but wants to make sure his system has all the elements to achieve a high performance culture in his entire factory.
This course includes 14 lectures that can be studied in about one and half hours. It also includes one quiz, that given the way it has been structured, I recommend you to take, not only to validate your understanding of the different topics covered, but also to give yourself the opportunity to review ideas that might not have been thoroughly covered by the lectures.
In summary, at the end you will be able to....
This is the second course related to the design and implementation of a system to support high performance teams. Between the first course on Designing the Team System and this second course about Implementing a System to Support High Performance Teams, there are over 40 lectures and more than two hours of video conferences. The objective of this second course is to give the student a general overview of the implementation process, and although it would be useful for the student to have completed the first course on System Design, this is not a requirement.
This second course is presented in a basic language and it will be good for engineers in factory environments, where teams are being implemented for the first time. It will also help more advanced factory employees, that already have teams, to verify their systems are complete and all the elements are correctly aligned.
These two courses provide a very good understanding of the high performance team implementation process, however this instructor recommends that if anyone is going to actually attempt to implement teams, to gather a group of participants with some previous experience and even perhaps, an external consultant.
This page describes the content of this course on high performance team implementation.
This document provides a sample of the Design or System Manual, developed in the first course of this series, about the design of the system to support high performance teams.
Definition of high performance teams.
High performance teams are work groups that are structured and trained to manage key metrics of their work areas, with the purpose of improving their own performance, and also with the objective of improving the financial results of their organizations.
This second course, explains step by step, each of the tasks required to implement a system to support high performance teams. This course is designed for engineers in factory environments that are about to launch a team implementation project and that need to become acquainted with the activities needed to achieve good results. It is also useful for engineers and employees in more advanced factories, which might have already developed teams. In this case, this course will help them validate all the elements fo their system and make sure they have aligned those elements correctly.
This lecture explains the contents of an implementation plan.
Please review a sample implementation plan included in the resources section of this lecture.
This is the first, and one of the most important steps in the team system implementation process. The project launch sessions will show the commitment of the management team to develop this project. It will be the opportunity for the management team to explain the strategic analysis done for the company and how the selected strategies are going to be implemented all the way down to the shop floor. The management team will also explain how the team development strategy will bring all the other strategies together, to make the entire culture change process successful.
It is important to explain all the ideas in the System Manual to the supervisors, so they understand quite well the system elements and the interactions between them. This is the most important group to be trained, because the supervisors are going to be at the center of the culture change process.
Supervisors need to be trained also on the contents of the Metrics and Tasks manual for the star point leaders, and on their own Work Plan or Game Plan for Supervisors. They also need to understand how to grade the team´s empowerment plans and how to use the different audits designed to evaluate team performance.
Additionally to being at the center of the team implementation process, the supervisors are going to see their role changing significantly. They will stop "pushing production out the door" to become people and team developers.
This lecture explains how this role change happens and why it is so important for the supervisors to understand what is going to happen to them.
It is very important also for the supervisors to have a document that can guide them through this complicated role change. Many supervisors are going to struggle, and their Work Plan is going to be very helpful to keep them on track and to remind them of all the activities they need to execute, without getting lost.
This lecture explains the process to train the teams to become high performance. It describes in detail all the activities, documents and ideas that need to be covered during the team´s initial training.
This team training session is the basis for a successful team and it needs to be planned and executed carefully, so the teams understand what is the challenge in front of them.
This lecture explains the process to train the administration support teams.
The support teams are groups of administration employees, usually engineers, that support the daily activities of the shop floor teams, so the production teams can achieve their targets. This is the reason why the support teams are sometimes called productivity or flow teams.
This lecture explains the design of the boards to be used by the teams on the shop floor, to register and control the metrics they have been assigned.
This lecture explains the documents that need to be filed by the teams. These documents are going to be needed by the team to understand their own development process and to demonstrate to external auditors, how they are executing the tasks and improving the metrics that have been delegated to them.
This lecture explains the daily and weekly activities that need to be carried out by teams, in order to support the monthly evaluation process.
The monthly evaluation process is very important because it provides hard evidence of the way the team is improving the metrics delegated to them on the empowerment plan, and also because it is the base for team rewards and recognition.
The empowerment plan contains all the tasks and metrics delegated to the team. It also explains the way to grade the performance of the team depending on the progress they make with each metric.
Please review the sample empowerment plan for a Quality Star Point Leader included in the resources section of this lecture. The empowerment plans for the other Star Points are going to be very similar, only that the specific tasks and metrics will be those relevant to each expert.
This lecture explains the way to evaluate the progress you are making with the implementation of the team system.
Please check the sample implementation progress audit included in the resources section of this lecture.
This is another important lecture. It provides you with strategies to protect the project from different types of threats that are going to appear at any time during the implementation process.
If handled correctly, this threats are going to be mitigated and the teams will be able to continue growing and providing the savings that contribute to the financial success of the factory.
This is another very important lecture in this course. It provides you with a good idea of the savings that are going to be generated by the teams, given the current performance baselines.
Please review the savings parameters indicated on the document included in the resources section of this lecture.
Definition of the most important terms and concepts used throughout this course.
Mechanical Engineer (ME) graduated at Georgia Tech in Atlanta, GA. Master in Business Administration graduated at IMD, International Management Institute at Luasanne, Switzerland. Twenty five (25) years of experience as Plant Manager and Campus Manager, working for multinational companies like Johnson Controls (Building Efficiency) and United Technologies (Carrier)
Successful implementation of over 50 high performance teams in seven factories. Successful transfer of several product lines including ramping up new green field factories. Successful implementation of Safety, Quality Assurance, and Constant Improvement systems, supported by Lean Tools and a High Performance team based culture.
Rodrigo has also written an eBook on productivity available in the Amazon Kindle platform. The productivity strategy explained in this book is also a team based strategy.