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Self Directed Work Teams

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Presentation on theme: "Self Directed Work Teams"— Presentation transcript:

1 Self Directed Work Teams
Lean Six Sigma in a Self Directed Work Force

2 GE … a tradition of excellence
Founded in 1878 as the Edison Electric Co. 130 years of successful operation 300,000+ employees worldwide Strong technology focus … Research centers in Germany, India, China and the U.S. First Carbon Filament Light Bulb, 1879 2

3 A heritage of innovation
1879 Thomas A. Edison invents carbon- filament incandescent lamp 1913 Develops X-ray tube & first commercially practical X-ray device 1941 Develops first US jet engine 1952 Develops LEXAN® polycarbonate resin—a transparent plastic 1962 GE invents solid state laser 1983 Develops magnetic resonance imaging 2004 Introduces the GE90-115B, the world’s most powerful jet engine GE founded in 1878 as Edison Electric Company … Today 300,000+ employees and $173 billion revenues

4 Why 6s ? Jack Welch’s “Vision 2000”
“Quality is the next opportunity for our Company to set itself apart from its competitors . . . ... Dramatically improved Quality will increase employee and customer satisfaction, will improve share and profitability, and will enhance our reputation. ... This Quality drive will require the passionate commitment of all of you to make it happen A Six Sigma 2000 target will require a significant commitment of resources and your strong, highly personal commitment to the objective.” J.F. Welch, 10/15/95

5 In the end you need both to create a world-class business.
Lean and Six Sigma Two separate improvement approaches… They both can help you improve your processes. Depending on what you want to improve, you either choose one of the two or both. …that are strong together Six Sigma can help Lean to reduce waste by improving the process capability in processes in the value stream. Lean can help Six Sigma to increase process capability by eliminating waste in processes. In the end you need both to create a world-class business.

6 Self Directed Work Teams
“Increasing employee involvement through self-directed work teams is not only a good thing to do, it is a business thing to do.” Ron Williams, 3M Quality Manager Greater Flexibility Reduced Operating Costs Faster Response to Change Fewer, Simpler Job Classifications Better Response to Workers’ Values Increased employee commitment to the Organization Ability to attract and retain the best people

7 GE Durham Paintfest Staff Team building at Jordan Lake
Health Awareness Day Durham Bulls Day Kids to Work ‘08 Durham Family Day Sept’08 Special Olympics Plane pull at RDU ‘08

8 Durham’s History ‘93 ‘94 ‘99 ‘02 ‘03 ’04 ‘08
Constructed in 1972 for GE Energy PS Steam Turbines 500 acres of land 500,000 sq. ft. of floor space Site opened for assembly of aircraft engines DEF ships first GE90 & CF6-80C2 DEF ships first CFM56-7 & CF34-8C GE90-115B CF34-8D/E CFM56-5 CF34-10 GP7000 CF6-80C2 L1F LMS100 GEnx ‘ ‘ ‘ ‘ ‘ ’ ‘08

9 Growth thru Lean Zero Additional Footprint & Double Digit Productivity
Engine Output 1995 1997 1999 2001 2003 2005 2007 2009 Zero Additional Footprint & Double Digit Productivity

10 Commercial Products GEnx GE90 GP7200 Support CFM56-5/7 CF34-10 CF34-8
Horizon Raven Synergy Heritage Support GEnx GP7200 CF34-10 CF34-8 CFM56-5/7 Liberty Odyssey Phoenix Freedom Summit Apollo Intrepid Mirage

11 High Performance Team Flat Organization Self Directed Workforce
Flexible Culture Multi-skilled Talent Boundryless Structure Improvement Driven Culture Odyssey Apollo Summit GP7200 Intrepid Mirage Freedom Raven Heritage Synergy Horizon Phoenix Liberty GEnx

12 Councils..Facility Wide Decisions
People Processes Human Resources Discipline & Development Training Tool & Gauge Materials One Representative per team Rotate members every 12 months Weekly Meetings Quality Safety Quality Systems Nonconforming Delivered Quality Environmental, Health & Safety

13 Technician Deliverables
Assemble Engines Meet business objectives Track incoming material shortages Develop schedules to meet ship dates Create & maintain operation planning Acquire tools & components Coach & train other team members Ensure quality of parts & engine build Perform inspections Ship to Peebles Test Operation Conduct post-test fault reviews

14 Technician Growth Opportunities
Tech III Advanced Assembly Skills Machining Computer Systems Personal Development Business Initiatives Personal Logbook Assessment Process Tech II Advanced Assembly Skills Machining Tech Writing Personal Development Computers Quality Systems Leadership Roles Tech I Basic Assembly Skills Finance Computers Team Building Skills Quality Systems EH&S Compliance Tech Two-week training before build Extensive training matrix “P” License Required > 9 months < 9 months < 2 year < 4 year Pay Increase with Achievement of Each Level

15 Communication Tools Communication Training Customer Visits Videos
& Voic DEF Business Review

16 Flexibility Multi Skilling Flex Time PB Days 360 Feedback
Extensive Training

17 Double digit productivity
Continuous Improvement Culture Safety Zero Injuries Double digit productivity Results Lean Six Sigma Quality

18 GEnx Flow Line 250% Reduction in Footprint & Utility Costs Summer ‘07
1/8th Scale Model Today 250% Reduction in Footprint & Utility Costs

19 Team Metrics… Drive Accountability
Reward & Recognize

20 Our Workplace Community
Team Cookouts Xmas Lunch GE Volunteers “Family Feud Game” Team Competitions Veterans Day Casino Night Qtr Point Celebration


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