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when using this file. Thank you.

• Will Lichtig

Built in Quality –Getting Things Done Right

OUTLINE

Our Approach to Built-in Quality (BiQ)–Key Points/Questions

Challenges We Have Faced–Key Points/Questions

Learning Exercise – Making the Perfect Cup of Coffee –Key Points/Questions

Lean “Quality” at Home

What is “Quality”?

Consistently producing a product (outcome) that meets the Customers’ expectations and is fit for the purpose intended.

Applying Lean Thinking

Lean ProductionPlanning &

Control

ProblemSolving

Purpose of BiQ –

• Information• Access/Space• Prior Work

(handoffs)• External

Approvals

•Material•Equipment/Tools•Methods/Skills•Labor

Provide Worker Everything Needed to Succeed:

Expectations

DesignOperations

Results

Reject

Perform Work Inspect

BiQQA/QC

Layout

Identify Operations, Break Into Tasks

OrderMaterial

BottomTrack

TopTrack

Install Studs

Frame Interior Full-Height Walls

Expectations

DesignOperations Results

Reject

Perform Work Inspect

BiQQA/QC

Customerso Traditionalo Externalo Internal

Conditions of Satisfaction Sources

o Documentedo Undocumented

Product Checklist

Step 1 - Expectations

Expectations

DesignOperations Results

Reject

Perform Work Inspect

BiQQA/QC

Past Failures Possible Counter Measures

o Poke Yoke/Error Proofingo Verification/“Testing”

Produce Standard Work Design Training Program Design Audit Program

Step 2 – Design Operations

Expectations

DesignOperations Results

Reject

Perform Work Inspect

BiQQA/QC

First Run Study “Game Tape” Process Audit (process) Inspect (product) Reflect & Adjust

Step 3 – Perform Work & Learn

Identify Customers For Product (User, A&E, IOR, Trade)

Customer(s) Confirm Product COS Performer Confirm w/ Customer(s)

Intellectual Understanding of Product COS

Performer Explore Product COS Options to Improve Production Ability

Customer(s) and Performer Revise or Confirm Product COS

Performer Develop Product Quality Checklist

Customer(s) Confirm that Checklist Expresses Product COS

Customer(s) Identify Past Failures Performer Identify Internal Past

Failures Performer Design Process to

Produce Product COS Performer Confirm Process

Counter-measures Address Past Failures

Performer Physically Test Process to Evaluate if Produces Product that meets COS

Customer(s) Confirm That Physical Test Satisfies COS

Performer Adjust Process Based Upon Test Results

Performer Develop “Mistake Proof” Devices or process to Assure Process/Product Quality

Performer Develop Process Checklist including essential features/past failures

Performer Develop Visual Controls for “Complete”

Performer Develop Assessment Protocols (Self, Foreman, Boldt, Next Trade, A/E, IOR)

Performer Develop Mistake Reporting System for Process & Product to PDCA

Performer Develop Swarm Response to Product Failure (Who + What, Fix-it, 5Y-it, Adjust Process, Notify)

Performer Develop Training For Foreman & Labor to Assure Understanding of Product & Process COS

First Run Study/Mock-up to Field Test

Identify variance, take action to correct

Product Process Control

Example – BiQ Field Book

First Run Study – Applying PDCA

Problem Solving

Framing Innovation

What Did You Learn

Key Points/TakeawaysQuestions

IMPLEMENTATION

My experience and lessons learned.

IMPLEMENTATION

We know how to build it!

IMPLEMENTATION

IMPLEMENTATION

Lesson 1: If the work scope seems easy it does not mean that doing a BiQ is quick and easy!

IMPLEMENTATION

Ok, I’ll tell you!

IMPLEMENTATION

Install top track, bottom track and studs in between.

IMPLEMENTATION

IMPLEMENTATION

Lesson 2: Avoid assumptions!

IMPLEMENTATION

We did this already!

IMPLEMENTATION

IMPLEMENTATION

IMPLEMENTATION

Lesson 3: You are responsible for finishing BiQ, printing it and checking that it’s used.

IMPLEMENTATION

Thanks!

Implementation

Challenges– I know how to build it, this was approved before, I do this all

the time.– Knowledge is king

Successes– Actual field use– Learn from challenges, and pay it forward

Learnings– Trust, Paradigm shift, Why – The more knowledge the collective team has, improves

results

What Did You Learn

Key Points/TakeawaysQuestions

The Perfect Cup of Coffee, Please

Develop a BiQ for that Perfect Cup

Roles– Facilitator– Coffee Drinker– Material Supplier (consumables)– Equipment Supplier (durables)– Coffee Production Team

Tools– Process Map– BiQ Worksheets– BiQ Development Checklist– Coaches

Layout

Identify Operations, Break Into Tasks

OrderMaterial

BottomTrack

TopTrack

Install Studs

Frame Interior Full-Height Walls

Customers• Traditional• External• Internal

Conditions of Satisfaction

Sources• Documented• Undocumented

Product Checklist

Past Failures Possible Counter Measures Poke Yoke/Error Proofing• Verification/

“Testing” Produce Standard

Work Design Training

Program Design Audit

Program

First Run Study “Game Tape”

Process Audit (process) Inspect (product) Reflect & Adjust

Expectations Process Control

What is a “Cup”?

What is a “Cup of Coffee”

What type of “bean”?

Bean (Green or Roasted), Ground or Instant, Caf or De?

Water?

“Equipment”

Converting Raw Materials

Supporting Tools

Black or . . .

“Sweetener”?

Finish . . .

What Did You Learn

Key Points/TakeawaysQuestions