2012 LEAN FORUM2012 LEAN FORUM

THE MAKINGTHE MAKINGOF 100,000+OF 100,000+PROBLEMPROBLEMPROBLEMPROBLEMSOLVERSSOLVERSJabil’s Lean Six Sigma Body of KnowledgeJabil’s Lean Six Sigma Body of Knowledge

•• Regional Lean Six Regional Lean Six Sigma Manager, EuropeSigma Manager, Europe

•• Leads Lean Six Sigma Leads Lean Six Sigma

NORBERTNORBERTDURBAKDURBAK

Education and Certifications:Education and Certifications: •• Leads Lean Six Sigma Leads Lean Six Sigma deployment in Europe deployment in Europe for Jabilfor Jabil

•• 12 years of experience 12 years of experience in engineering and Lean in engineering and Lean manufacturingmanufacturing

Education and Certifications:Education and Certifications:

•• MS in Mechanical MS in Mechanical Engineering with Engineering with specialization in Electronics specialization in Electronics and Automationand Automation

•• ASQ Certified Six Sigma ASQ Certified Six Sigma Black BeltBlack Belt

Third Third largest largest electronic electronic manufacturing services manufacturing services providerprovider

•• 60 sites in 22 countries60 sites in 22 countries•• 60 sites in 22 countries60 sites in 22 countries

•• + 100,000 employees+ 100,000 employees

•• 160 160 customerscustomers

•• $$16.5 billion in 16.5 billion in revenuerevenue

•• Founded in 1966 in MichiganFounded in 1966 in Michigan

WHY WHY LEAN LEAN LEAN LEAN SIX SIGMA?SIX SIGMA?

$10 000

$12 000

$14 000

$16 000

$18 000

JABIL‘S GROWTHJABIL‘S GROWTH

(000,000’s)

$16.5 BILLION$16.5 BILLION

$0

$2 000

$4 000

$6 000

$8 000

$10 000

(000,000’s)

“World’s “World’s leading leading global manufacturing global manufacturing

OUR VISIONOUR VISION

global manufacturing global manufacturing services provider”services provider”

VVisionision and Guiding Principlesand Guiding PrinciplesVision: Focus on elimination of waste and cost reductions, improving effectiveness through training, and optimization

of processes.

11stst InitiativeInitiative(global)(global)

22ndnd InitiativeInitiative(two divisions)(two divisions)

Onboarded remaining Onboarded remaining divisiondivision

Lean Office Lean Office MBBs hiredMBBs hired

Plant and Regional Plant and Regional Lean Managers hiredLean Managers hired

Champion Champion TrainingTraining

JABIL‘S LEAN JOURNEYJABIL‘S LEAN JOURNEY

………… 20092009 20102010 2011201120052005 20122012

Black Belt Black Belt CertificationsCertifications

Lean Silver Lean Silver CertificationsCertifications

Lean BronzeLean BronzeCertificationsCertifications

Best Practices Best Practices Competition LaunchCompetition Launch

•• 7 Steps to Eliminating Waste7 Steps to Eliminating Waste•• CompanyCompany--widewide•• SiteSite--managedmanaged•• Created awarenessCreated awareness

AWARENESSAWARENESS

UNDERSTANDINGUNDERSTANDINGUNDERSTANDINGUNDERSTANDING

CULTURAL CHANGECULTURAL CHANGE

HOW TOHOW TOMAKEMAKE 100,000+100,000+PROBLEMPROBLEMMAKEMAKE 100,000+100,000+PROBLEMPROBLEMSOLVERS?SOLVERS?

•• Create an organizational structureCreate an organizational structure•• Alignment and deploymentAlignment and deployment•• Define body of knowledge and the Define body of knowledge and the

STRUCTURED EDUCATIONSTRUCTURED EDUCATIONIS KEYIS KEY

•• Define body of knowledge and the Define body of knowledge and the education roadmapeducation roadmap

•• Deploy the program starting with Deploy the program starting with middle managementmiddle management

•• Share and recognize resultsShare and recognize results

Divisional Directors(Global Operations)

2

Divisional Directors(Global Operations)

2

Lean OperationsLean Operations Lean OfficeLean Office

ORGANIZATIONAL ORGANIZATIONAL STRUCTURESTRUCTURE

Global Team7

Global Team7

Regional Lean Managers

6

Regional Lean Managers

6

Plant Lean Managers

60

Plant Lean Managers

60

Master Black Belts3

Master Black Belts3

Black Belts+90

Black Belts+90

Supply Chain1 MBB

Supply Chain1 MBB

IT1 MBB

IT1 MBB

Finance1 MBB

Finance1 MBB

•• Global Lean CouncilGlobal Lean Council•• Plant Lean CouncilsPlant Lean Councils•• Functional Lean CouncilsFunctional Lean Councils

–– Business Business UnitUnit

ALIGNMENT AND ALIGNMENT AND DEPLOYMENTDEPLOYMENT

–– Business Business UnitUnit–– FinanceFinance–– ITIT–– Supply Supply ChainChain • Convert Strategy to Action

• Consensus on Targets• Prioritization of Pipeline• Infrastructure• Project Status

BODY OF KNOWLEDGE

ChampionTrainingChampionTraining

Breakthrough Breakthrough InitiativesInitiativesTop

ManagementTop Management

Middle Middle

FocusFocus

Lean Six SigmaCertificationTraining

Lean Six SigmaCertificationTraining

Shop FloorCertificationTraining

Shop FloorCertificationTraining

Live the Guiding

Principles

Solve Problems Effectively

Maintain Improvements

Continuously Improve

Middle Managementand Supervisors

Middle Managementand Supervisors

Front-line OperatorsFront-line Operators

Top ManagementTop Management

Middle Managementand Middle Managementand

Basic knowledge and application of principles, concepts, and lean tools.

Capable in applying and coaching lean principles and

tools throughout an entire value stream

Strategic, focused knowledge and solid understanding of all aspects of lean transformation

BronzeBronze SilverSilver GoldGold

Champion TrainingChampion Training

6 months 6 months 6 months

EDUCATION ROADMAPStrategic support to drive lean

transformation3 days

and Supervisorsand Supervisors

Front-line OperatorsFront-line Operators

Capable to implement incremental improvements and

maintain gains

Shop FloorShop Floor

Capable in applying and coaching advanced problem

solving

Black BeltBlack BeltBased on:

1 week

6 months

Top ManagementTop Management

Basic knowledge and application of principles, concepts, and lean tools.

Capable in applying and coaching lean principles and

tools throughout an entire value stream

Strategic, focused knowledge and solid understanding of all aspects of lean transformation

BronzeBronze SilverSilver GoldGold

6 months 6 months 6 months

Strategic support to drive lean transformation

Champion TrainingChampion Training

3 days

CHAMPION TRAINING

Middle Managementand Middle Managementand

Content: o Leadership in the transformational processo Strategic Deployment & Alignmento Champion’s role

Content: o Leadership in the transformational processo Strategic Deployment & Alignmento Champion’s role

Capable to implement incremental improvements and

maintain gains

Shop FloorShop Floor

Capable in applying and coaching advanced problem

solving

Black BeltBlack BeltBased on:

1 week

6 months

and Supervisorsand Supervisors

Front-line OperatorsFront-line Operators

Middle Managementand Middle Managementand

Capable in applying and coaching lean principles and

tools throughout an entire value stream

Strategic, focused knowledge and solid understanding of all aspects of lean transformation

BronzeBronze SilverSilver GoldGold

Strategic support to drive lean transformation

Champion TrainingChampion Training

Basic knowledge and application of principles, concepts, and lean tools.

6 months

3 days

6 months 6 months

Content: o Trainingo Application (5 projects)

Content: o Trainingo Application (5 projects)

BRONZE TRAININGTop ManagementTop Management

and Supervisorsand Supervisors

Capable to implement incremental improvements and

maintain gains

Shop FloorShop Floor

Capable in applying and coaching advanced problem

solving

Black BeltBlack BeltBased on:

1 week

6 months

o Application (5 projects)o Certification Examo Application (5 projects)o Certification Exam

Front-line OperatorsFront-line Operators

Middle Managementand Middle Managementand

Capable in applying and coaching lean principles and

tools throughout an entire value stream

Strategic, focused knowledge and solid understanding of all aspects of lean transformation

BronzeBronze SilverSilver GoldGold

Strategic support to drive lean transformation

Champion TrainingChampion Training

6 months

3 days

6 months 6 months

Basic knowledge and application of principles, concepts, and lean tools.

SILVER TRAININGTop ManagementTop Management

Content: o Trainingo Application (5 projects)o Certification Exam

Content: o Trainingo Application (5 projects)o Certification Exam

and Supervisorsand Supervisors

Capable to implement incremental improvements and

maintain gains

Shop FloorShop Floor

Capable in applying and coaching advanced problem

solving

Black BeltBlack BeltBased on:

1 week

6 months

Front-line OperatorsFront-line Operators

o Certification Examo Certification Exam

Middle Managementand Middle Managementand

Capable in applying and coaching lean principles and

tools throughout an entire value stream

Strategic, focused knowledge and solid understanding of all aspects of lean transformation

BronzeBronze SilverSilver GoldGold

Strategic support to drive lean transformation

Champion TrainingChampion Training

6 months

3 days

6 months 6 months

Basic knowledge and application of principles, concepts, and lean tools.

BLACK BELT TRAININGTop ManagementTop Management

Content: Content: and Supervisorsand Supervisors

Capable to implement incremental improvements and

maintain gains

Shop FloorShop Floor

Capable in applying and coaching advanced problem

solving

Black BeltBlack BeltBased on:

1 week

6 months

Front-line OperatorsFront-line Operators

Content: o Trainingo Application (1 project)o Certification Exam (ASQ)

Content: o Trainingo Application (1 project)o Certification Exam (ASQ)

Basic knowledge and application of principles, concepts, and lean tools.

Capable in applying and coaching lean principles and

tools throughout an entire value stream

Strategic, focused knowledge and solid understanding of all aspects of lean transformation

BronzeBronze SilverSilver GoldGold

Strategic support to drive lean transformation

Champion TrainingChampion Training

6 months

3 days

6 months 6 months

SHOP FLOOR TRAININGSHOP FLOOR TRAINING

Middle Managementand Middle Managementand

Top ManagementTop Management

Front-line OperatorsFront-line Operators

Capable to implement incremental improvements and

maintain gains

Shop FloorShop Floor

Capable in applying and coaching advanced problem

solving

Black BeltBlack BeltBased on:

1 week

6 months

and Supervisorsand Supervisors

Content: o Kaizen blitzo Problem solvingo 5So Standard work

Content: o Kaizen blitzo Problem solvingo 5So Standard work

LEAN SIX SIGMA

COMMUNICATIONCOMMUNICATION

Single data Single data repository for all repository for all Lean Six Sigma Lean Six Sigma information. information.

RECOGNITIONRECOGNITION

RESULTSRESULTS

+6,500Bronze Candidates in Training

+45Silver Candidates in Training

+360Bronze Certified

+4,000Passed Bronze Exam

+90ASQ Black Belt Certified

+14,600Kaizen Events

•• Make it an enterprise initiativeMake it an enterprise initiative•• Visible commitment of the executive teamVisible commitment of the executive team•• Educate, empower and involve employeesEducate, empower and involve employees•• Flexible structureFlexible structure

KEY TAKEAWAYSKEY TAKEAWAYS

•• Flexible structureFlexible structure•• Communicate, show results and Communicate, show results and

continuously improvecontinuously improve•• Recognize and celebrate successesRecognize and celebrate successes

CONTACTCONTACT

NORBERT DURBAKNORBERT DURBAKEmail: Norbert_Durbak@Jabil.comEmail: Norbert_Durbak@Jabil.com

www.jabil.com