How a manufacturing plant went about a 200%+ improvement in employee engagement / problem solving

1. The Value of
Employee
Engagement
How to turn 600 people
into 4000+ improvements

2. Diabetes Care – Holdrege, NE
350,000 sq.ft
620 employees
Largest diabetic
syringe
manufacturer in
the world

3. Agenda
Handle a large volume of kaizen ideas through gradual
use of manual to IT solutions.
How to keep the program increasing quality and
quantity every year
How a rewards system can help to motivate
"Exceptional" kaizens and identify stand out employees
Think of Kaizens as problem solving practice for every
employee
To use Kaizen's as a coaching / mentoring opportunity
to increase management / shop floor cooperation.

4. In the Beginning…
• Most Companies Start with a
“Suggestion Program”
• Suggestions are fine, but actual
improvements are better..
• Improvements are great, but learning
from them is outstanding…
• Getting everyone to learn how to make
improvements while learning from
them – now that’s ideal.

5. Background
Kaizen
Action
Sheets
(KAS)
Started Manual
Lot’s of Training
Lots of Publicizing

6. Speaking of Publicizing…
• Keeping in a spirit of “Fun” the teams began creating posters
that often were spins on the popular “pop” culture
advertisements back then…
• The following slides show an example of just how “corny”
and how much fun our team members had getting into the
“Kaizen Spirit”.

7. They’re
Grrrreat!

9. 1,000,000 Syringes out the door
$1000
1 Barrel on the Floor
$0.001
1 Accident Avoided
Priceless

10. Aren’t you glad you use KAS?
Don’t you wish everyone did.

11. I’ve got great News!
We saved a bunch of money
by switching to KAS!

13. It ain’t easy bein’ Green.

15. Mmm, Mmm….Good!

17. Long day?
KAS can
fix that.

19. And yes, even Games

20. What did this get us?
BD - Holdrege Submitted KAS
2000
1800
1600
1400
1200
1000
800
600
400
200
0
175% Increase!
2006
2007
2008

21. Our KAS System needed Kaizen

22. IT Solutions

23. KAS Database

24. Remove the Constraint and…
BD - Holdrege Submitted KAS
4500
4000
3500
10 per emp
10 per emp
Another 123% Increase!
3000
6 per emp
2500
4 per emp
2000
1500
2 per emp
1000
1 per emp
500
0
2006
2007
2008
2009
2010
Implementation Rate of all ideas has run 97-98% since 2009
2011

25. Recognition Program
CI coordinator
Team Leader
KAS winner
Manager
BD Holdrege Kaizen reward program
changes every year.
2010 (small prizes for # of Kaizens)
2011 (Big Prizes) TV,BBQ,Laptops
2012 (Cash rewards) $50 - $350
Receive a certificate of appreciation
signed by Plant Manager and CI
Leader
Tip: Have Vision project every year on
how to engage associates in Kaizen
program

26. Holdrege FY12 Kaizen Program
• 4 KAS
• Reward Program
(Direct deposit with next pay-check)
•
•
•
Monthly lottery (random) drawing of $50
Monthly Exceptional drawing of $350
Quarterly Safety Kaizen drawing of $350
•
The announcement of the winner will be made during the next Monthly Business
Communication meetings and also in our Ultra Fine Times Newspaper.

27. Exceptional Kaizen?

28. Kaizen as a Management Tool
Plant Manager Leader Standard Work
Activity
Safety
Quality
Task
incident reports on any new injury
Perform BBS Observation for Team
Member
Change Control
Monthly Weekly
Daily
As Needed
Mon Tue Wed Thr Fri
X
X
X
review one CAPA implemented actions
where implemented (when applicable)
X
X
Attend a PVD Board Meeting
X
Morning Board Walk
Walk one whole Value Stream
20 Keys Audit one Line
(may piggyback w /staff)
X
X
X
X
Productivity Ops Review
Review TRS Process on one cell
X
X
X
X
X
CI Review
X
Inspire on KAS / SAR with team member
X
Review / Challenge Skills Matrix
Review an implemented KAS/SAR with
responsible employee on the floor
Review Lean Blitz on floor with team
Verify / Challenge WIP levels on in one
cell
Coach / Mentor a Subordinate through
solving a problem
Development Give positive feedback to at least one
employee
One on One with Managers
X
Kaizen
X
X
X
X
X
X
X
X

29. In Summary
Ensure project completion and share results
Encourage participation – be involved
Focus on 1 Kaizen at a time
Give feedback / communication
Develop a system (dB) to keep track of progress
Have Fun