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People Development


Operator errors caused quality defects and plant inefficiency

New hire training was too slow to meet additional production needs


Documented Plant

Process Documentation; best practices

My Job Check Lists:  each person documented the activities needed to complete their jobs.  Lists were posted at each work station.

Change Over Check Lists:  developed by leads to coordinate shift and product change overs

Glossary of Terms; let’s use the same words for clear communication


Train and follow up to close gaps

Know what to do, Know how to do it, Know when to do it, Do it



Communicate Results:  Visually

Every Person Knows Today’s Results When They Go Home

Communicate Issues:  Prominently

Flip Charts on Line

Team based solutions:  Participation

Post Actions Taken and Outcomes



Reduced errors and omissions

Reduced quality holds

Improved plant performance