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Process Improvement via an Industry Cooperative Exchange

Process Improvement via an Industry Cooperative Exchange. Phil Love. © Sikorsky Aircraft Corporation. Overview. The Need The Method Examples Summary. The Need. Image from: blogs.usatoday.com/oped/people_forum/. The Goal. Image from: blogs.usatoday.com/oped/people_forum/.

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Process Improvement via an Industry Cooperative Exchange

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  1. Process Improvement via an Industry Cooperative Exchange Phil Love © Sikorsky Aircraft Corporation © Sikorsky Aircraft Corporation

  2. Overview The Need The Method Examples Summary © Sikorsky Aircraft Corporation

  3. The Need Image from: blogs.usatoday.com/oped/people_forum/ © Sikorsky Aircraft Corporation

  4. The Goal Image from: blogs.usatoday.com/oped/people_forum/ © Sikorsky Aircraft Corporation

  5. Market Feedback © Sikorsky Aircraft Corporation

  6. FACILITATOR Focuses on process Helps the Team get more done in less time Promotes team building, trust, and win/win approach Process Improvement Team PROCESS Process Leadership Participation & Involvement Content Leadership TEAMWORK AND RESULTS • TEAM MEMBERS • Contribute ideas and expertise • Help Team Lead get where he/she wants to go • Follow the process • TEAM LEAD • Makes Decisions • "Owns" the problem • Focuses on content DECISION MAKING CONTENT © Sikorsky Aircraft Corporation

  7. Analyze Design Pilot Test Implement Change time Four-Step Process 1 2 3 4 Analyze Current State Design a “Future State” Pilot Test the “Future State” Implement Changes • Describe the process • Determine R&Rs • Surface problems with Current Process • Generate ideas for improvement • List key metrics • Gather existing templates • Benchmark others • Identify tasks to start earlier in the process • Share Best Practices / Benchmarking learnings • Develop a draft ‘future state” • Revise & edit • Create new templates / forms to be used • Establish Future State #1 & draft training plan © Sikorsky Aircraft Corporation

  8. I O C S P Analyze This: The “SIPOC” Model 1 “The Process” (“As-Is”) Suppliers Inputs Outputs Customers … Things needed to start A series of steps The result © Sikorsky Aircraft Corporation

  9. #17 Your Issue --------------------------------------------------- - JL #17 Your Idea --------------------------------------------------- - JL Future State Design 2 “The Process” (“As-Is”) Inputs 1) ~~~~ 2) ~~~~ 3) ~~~~ Outputs … Standard Work Problems Design a “Future State” Ideas for Improvement © Sikorsky Aircraft Corporation

  10. Future State Design 2 Inputs 1) ~~~~ 2) ~~~~ 3) ~~~~ 4) ~~~~ “The Process” (“To Be”) Outputs … Analyze Why–Why-Why Surface Symptom IdentifyRoot Cause Design into “Future State” Generate Ideas Conduct Team Review © Sikorsky Aircraft Corporation

  11. A Work In Progress © Sikorsky Aircraft Corporation

  12. Test Drive and Roll-out 3 4 Analyze Current State Design a “Future State” Pilot Test the “Future State” Implement Changes • Conduct “test drive” with Future State #1 • Assess Future State plan for changes • Document changes & create Future State #2 • Estimate impact of new process on key metrics • Document changes with “rapid response” plan to execute • Immediate • “30 days” • “P3I” • Execute training plan • Roll-out new way • Measure © Sikorsky Aircraft Corporation

  13. Example: Missed Expectations I © Sikorsky Aircraft Corporation

  14. Analyze and Refine Process Current State with issues noted from joint working group Timeline Info Flow Org Lanes Process Steps Future State developed by joint working group Added joint CDRL planning steps during contracting phase © Sikorsky Aircraft Corporation

  15. Test Drive and Roll-out © Sikorsky Aircraft Corporation

  16. 4. 5. 6. 7. 8. 9. 10. 11. 12. 10. 13. Updated 14. 15. 16. 17. 18. 19. Updated 21. 21. Example: Missed Expectations II Entry / Exit Criteria Documented . . . © Sikorsky Aircraft Corporation

  17. Details Matter 22. But Not Understood. © Sikorsky Aircraft Corporation

  18. Joint Review of Entrance/Exit Criteria © Sikorsky Aircraft Corporation

  19. Implemented On Program © Sikorsky Aircraft Corporation

  20. Example: Lots of Metrics… … But Where Is The Info © Sikorsky Aircraft Corporation

  21. Finding the Information Metrics - 20 sources “Good Metrics” “Level 1 or PM metrics” 305 Organized by Program Phase 149 55 1ST review 2ND review • Mapping • Cataloging • Gap Analysis • Recommendation • Eliminated redundant metrics • Screened for key attributes • Screened for “forward-looking” characteristics Basket of Metrics © Sikorsky Aircraft Corporation

  22. Jointly Assess Value of Each Metric … then pilot and refine. © Sikorsky Aircraft Corporation

  23. PDR CDR RFP SRR SFR Requirements development timeline does not support low risk supplier effort Example: The Contracting Conundrum Potential Future State M/S B CA M/S B CA M/S Time Line RISK © Sikorsky Aircraft Corporation

  24. MS-A MS-B MS-C MDD Material Solution Analysis Preferred System Engineering & Manufacturing Development & Demonstration Technology Development Prototypes TRA PHASE I PHASE II PHASE III TRA PHASE IV PDR II IRR PDR I CDR FRR SVR / PRR SSR ASR SRR I SRR II SFR TRR ITR Improved SE Process AS IS • ENTER MS-B WITH AN IMMATURE SYSTEM SPECIFICATION • RESULTS IN LESS INFORMED MILESTONE DECISIONS • FOSTERS POORLY DEFINED PROGRAM ASSUMPTIONS & BASELINES • LEADS TO COST / SCHEDULE GROWTH DURING EXECUTION MS-A MS-B MS-C Concept Refinement Technology Development System Development & Demonstration SRR SFR PDR CDR TRR FRR SVR / PRR TO BE… • OUTPUT OF EACH PHASE MEETS INPUT CRITERIA FOR GATE REVIEWS • GREATER OPPORTUNITY FOR MATURING CRITICAL TECHNOLOGIES • ALLOWS FOR COMPETITIVE PRESSURES TO BETTER OPTIMIZE COST/SCHED/PERFORMANCE • GREATLY IMPROVED LIKELIHOOD OF MEETING COST/SCHED …START “SLOW” TO GO “FAST” *Note: Extracted from ENHANCED ACQUISITION PROCESSES, 14 February 2008, by RDML Steve Eastburg, NAVAIR Assistant Commander for Research and Engineering. © Sikorsky Aircraft Corporation

  25. MS-A MS-B MS-C MDD Material Solution Analysis Preferred System Engineering & Manufacturing Development & Demonstration Technology Development Prototypes PHASE I PHASE II PHASE III PHASE IV TRA TRA PDR II PDR I CDR IRR FRR SVR / PRR SSR SRR II ASR SRR I SFR TRR ITR Scaled from Cat I Programs to ECPs Vision Scaled … Requirements Maturation Joint SOW Development Design / Qual Execution … Detail Process Mapped Jointly… Timeline Info Flow Org Lanes Process Steps … And Piloted © Sikorsky Aircraft Corporation

  26. Process Integration AND Product Integration expected Integrated Processes consider the Customer Value Customer feedback Communication and common-sense are enablers Joint understanding of: System engineering processes Customer expectations Embrace opportunities to team with Customers Summary SEMP © Sikorsky Aircraft Corporation

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