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Applying a Lean Transformational Approach to a Transactional Process Mike Mosher Functional OpEx Leader Ingersoll Rand Joe D’Apollonio Value Stream Coach Ingersoll Rand
Applying a Lean Transformational Approach to a Transactional Process
Mike Mosher Functional OpEx Leader
Ingersoll Rand
Joe D’Apollonio Value Stream Coach
Ingersoll Rand
Our Lean Journey
• The Opportunity
• Ingersoll Rand’s Approach to Lean Transformation
• Secrets to Sustainability
• Adapting Lean to Transactional Processes
• Results and Key Learnings
The Opportunity
Do you see the opportunity?
75 days of cycle time
Is it within manufacturing?
Our Standard Approach 3-4 weeks
Core Team Development
3-4 weeks
Value Stream Analysis
2-4 weeks
Executive Lean
Workshop
Scope Value Stream
Site Level – Operational Excellence Deployment Plan (OEDP)
Value Stream Level – VS Performance A3
Regularly scheduled
Monthly Rapid Improvement
Events
Single Process Level – RIE A3
Ongoing
Ongoing Kaizen / Problem Solving
Problem Level – 9 Step Problem Solving A3
The Transformation Plan
Execution Through Mission Control
Standard Work
Improvement Activity
WHERE THERE IS NO STANDARD WORK, THERE IS NO IMPROVEMENT
Managing for
Daily Improvement (MDI)
WHERE THERE IS NO MDI, THERE IS NO SUSTAINMENT
Acknowledge the Differences Adapt Where Needed
Operational Definitions
Don’t let BEST get in the way of BETTER
Standard Work
Only 1 way
Slight Differences – RIEs
Cross Functional Multi SBU
Multi Region Process and Systems
Pre-Work
More
Event Week Post-Work
Longer
Results Windchill Cycle Time
Reduced 76%
Link Ticket Cycle Time
Reduced 80%
Link Ticket Process Steps
Reduced 63%
Windchill Rework
Reduced 65%
Key Learnings
• Apply the standard transformational approach
• A3 thinking works as well in the transactional world as it does in manufacturing
• Go to the Gemba to reduce resistance
• Acknowledge the differences; adapt where needed
• Seek perfection but don’t be stubborn; accept improvement
Questions?
Thank You!
Please complete the session survey at:
www.ame.org/survey
Session: ThP/40
Applying a Lean Transformational
Approach to a Transactional Process
Mike Mosher and Joe D’Apollonio
Ingersoll Rand
APPENDIX Applying a Lean Transformational
Approach to a Transactional Process
Culture of A3 Thinking Work Level
Develops & Manages
The Respective A3 Purpose
The site or function
level
Executive sponsors and senior leaders
Operational Excellence Deployment Plan
(OEDP)
Culture and capability
The end-to-end process
level
Value stream leaders
Value stream performance
Transformational improvements
The single process
level RIE team
Rapid Improvement Event (RIE)
Improvement
The problem level
Daily front-line operations and management
9 Step Problem Solving Variation/defect
reduction
