Featherlite Manufacturing Experiences the Power of A3
1/30/2008 -
FEATHERLITE MANUFACTURING EXPERIENCES THE POWER OF A-3!
Featherlite Manufacturing of Cresco recently completed training sponsored by NICC on the A-3 Problem Solving tool. The A-3 is a powerful yet simple problem solving tool developed by Toyota and taught to all their employees.
The term "A3" derives from the paper size used for the report, which is the metric equivalent to 11" x 17" (or B-sized) paper. Toyota actually uses several styles of A3 reports for solving problems, for reporting project status, and for proposing policy changes each having its own "storyline."
The A3 Process helps people engage in collaborative, in-depth problem-solving. It drives problem-solvers to address the root causes of problems which surface in day-to-day work routines. The A3 Process can be used for almost any situation, and when used properly (i.e., all of the steps are followed and completed), the chances of success improve dramatically. The following are some of the advantages to this tool:
A3 problem solving occurs as part of everyday work
A-3 works very well with small groups. Large numbers of staff do not have to be gathered for extended times to do speculative problem solving. Coaches can be recognized and easily trained to help staff validate and participate in the A3 process without leaving the workplace.
A3 problem solving is intuitive and easy to learn and remember
Most employees are not engineers or process-improvement specialists. The A3 process is logical thinking based on the scientific method of problem solving. It is easy to learn and teach.
A3 thinking means better and fewer meetings
Conducting a lean meeting using the A3 process can greatly reduce the time and numbers of meetings required. A3s are best done by a group of two to five people representing the affected parties. The group procures validation of the current condition and the target condition from peers.
The A3 process documents costs and benefits
The cost of the implementation plan is documented on every A3 and can be compared to the benefit. It can reflect hard or soft dollars saved, or be a measure of quality of service. This creates objective information for leadership to use in authorizing the implementation plan presented on the A3 document.
The A3 template helps us solve problems and document new processes
When the A3 document is kept in a three-ring binder in the department or work area, activities can be reviewed by auditors or regulatory groups, senior leaders, and staff from other departments. This promotes cross-departmental sharing of process changes and generates even more problem-solving ideas.
The A3 process is satisfying to everyone, particularly frontline workers
The A3 is easy to learn and easy to teach. Staff can use it to remove the frustrations of their daily work created by weak and unsupportive processes. Being involved with creating a better way to work has been exceptionally well received by frontline workers. Workers can see and appreciate the changes they participated in creating.
32 Featherlite employees had 10 hours of classroom instruction on constructing A-3’s along with coaching sessions over a 4-week period. The training and coaching was conducted by Vicki Baum from Indian Hills Community College. Each week the teams would report out on their projects to each other, and work one on one with Vicki to fine tune their A-3’s. On the 4th week the teams presented their projects to Featherlite Management. Here are comments from Management and participants on the outcome of the training:
“I think the A-3 provides our Production Management and Engineering group with a viable tool to use for problem solving at all levels of the organization. It provides a methodology and a common sense approach that will yield good results for our company.” - Dave Seegers, V.P. of Cresco Operations
“Lean Manufacturing and 5S have been very helpful in our manufacturing processes. I believe A-3 is the best tool that we have been exposed to so far. It is a program that has great potential in identifying and solving small and potentially big problems. It can be used in all kinds of settings from the office to manufacturing by all employees, not just management. It also produces fairly quick and lasting results. The bottom line is that A-3 alleviates a lot of frustration attached to processes, and you can see more clearly what you are dealing with.” – Randy Ferrie, Plant 3 Manager
“When attending the report-out sessions for the A-3 classes, I was truly amazed at how the employees took what they had learned, applied the process to particular areas, and came up with some truly spectacular time and cost saving ideas. We will definitely be using this tool for a long time to come and have already identified many future projects.” - Cindy Helmke, Human Resources Manager
“I think that A-3 is a very good tool for a manufacturing business. It is quick and easy to use and understand. You can put it to use on any kind of problem and see results within a short period of time. – Duane Gaul, Plant 2 Manager
To learn more about A-3 training through NICC, contact Tom Kammer at (800) 728-2256 Ext. 308, kammert@nicc.edu or Roberta Murray at (80) 728-2256 Ext. 313, murrayr@nicc.edu.
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