20 Keys

There is always an opportunity for doing things safer, better & more cost effectively

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ODI’s Johan Benadie recently did a SGA (small group activity) with the Creditors Team at Grain Field Chickens Head Office. Small group activity (SGA) with the Creditors Team at Grain Field Chickens (GFC) Head Office. Analysing the current procedure for processing creditor invoices, by following the Key 6 (Kaizen of Operations) methodology of the 20 Keys Operations Improvement System. Kaizen is about continuous improvement “for the better”, and Key 6 is, therefore, about continuously improving the way in which things are done. There is always an opportunity for doing things safer, better, more cost effectively, more time efficient, and smarter. […]

20 Keys

Johan Benadie and a SGA in Standerton

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ODI’s Johan Benadie is doing a small group activity at Goldi Primary Processing Plant in Standerton. The production team is responsible for packing a specific mix and quantity of a product on a production line. The challenge is to consistently pack the right quantity and mix into bags (48 pieces per bag) and cases (6 bags), and with the right quality. After observations on the line by the team and a root cause analysis, a different method of packing was applied. Feedback from packers and observations during the experiment indicated an increase in efficiency. This will also help with the […]

20 Keys

Implementation of model workplaces

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Implementation of model workplaces is an effective way in which to energise implementation of the 20 Keys system and to bring about quick and visible change. Such a model workplace must satisfy four requirements and these requirements are audited by a team of people which must include an ODI consultant, and if achieved, a certificate of achievement is awarded. To follow is a list of the various requirements: Requirement 1: Points on the Key 1 check-sheet The Key 1 check-sheet is used to determine the score on certification day. Requirement 2: Model desks, worktables and machines Model desks, worktables and […]

20 Keys

This is not an ice-cream factory

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Saw a good example today of the CAPDo cycle in action. Recently I did a 20 Keys progress review at Wispeco Profiles Department. It is quite a large workplace with five 5 extrusion press lines. Richard Muller and his team took the action list and meticulously scrutinised and implemented each action point. Review (Check) today a strong level 3.5, for a safe, efficient working and workflow, well organised and clean workplace. It is really satisfying to walk on the floor and being approached by operators asking what I think of their workplace? A day of happy people (and I am sure […]

20 Keys

There is always a way to innovate

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There is always a way to innovate yet there are many myths surrounding innovations and ideas for operations improvement in organisations. The 6th and last myth in our series of Myths vs Reality is: “An informal approach for getting ideas for improvement works best, with managers promoting big ideas, because small ones aren’t worth the time.” The reality is without a formal process for handling ideas, managers and employees face the challenge of figuring out how to deal with each idea that comes up. A simple and easy to use system for getting, recording, evaluating, supporting, tracking and giving recognition is most […]

20 Keys

Rewards based ideas vs sustainable ideas for improvement

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There are many myths surrounding innovations and ideas for operations improvement in organisations. One of those myths is: The best way in which to encourage ideas is to offer rewards based on the value of such ideas. The reality is that most companies that offer rewards for ideas get into big trouble. A system where a percentage of the value of an idea is given as a reward backfires in all sorts of ways, often with dishonesty and fraud involved. The most effective and sustainable ‘ideas for improvement’ systems offer no rewards for individual ideas. When a rewards-based system is discontinued due to […]

20 Keys

There are many myths surrounding innovations & ideas for operations improvement in organisations

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Operations improvement is a fundamental requirement, and requires continuous effort from any organisation that wishes to succeed in today’s environment of change and challenge. Yet, there are many myths surrounding innovations and ideas for operations improvement in organisations. The fourth myth in our series of Myths vs Reality is: “Creativity training results in more and better ideas from workers.” Reality is, most ideas are simple, common-sense solutions and responses to problems and opportunities that exist in the immediate workplace. Until a company can capture workers’ everyday ideas, creativity training to trigger more ideas can be a pointless and costly exercise. However, here is a warning – do […]

20 Keys

Do you think suggestion boxes are effective?

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Continuous improvement consists of initiatives and innovations to achieve best practices, but there are many myths surrounding operations improvement in organisations. The third myth in our series of Myths vs Reality is: “Suggestion boxes are effective for obtaining ideas for improvement” The reality is, suggestion boxes might be useful if you use it for comments about a new product name, or proposals for a new menu in the canteen, but practical experience indicates that it is not effective at all for generating ideas for operations improvement. I usually make a point of looking in boxes wherever they are used, and find almost 100% of the time […]

20 Keys

Do you think big ideas are where the action is?

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There are many myths surrounding innovations and ideas for operations improvement in organisations. The second myth in our series of Myths vs Reality is: “Big ideas are where the action is” Reality is, if you wait for big ideas only, you will wait for a long time, as they come along rarely, and unpredictably. Also, such ideas are easy targets for competitors, who quickly discover them, and counteract them. The real action lies with small ideas about quality, cost effectiveness, delivery, service and safety improvements, in and between functions in the organisation. Not only are there abundant opportunities for such ideas, they are proprietary, and they […]

20 Keys

Myth or reality? Managers are in the best position to come up with ideas…

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There are many myths surrounding innovations and ideas for operations improvement in organisations. One of these myths is: Managers are in the best position to come up with ideas The reality is, employees are in the best position to come up with ideas for operations improvement because they are the ones actually doing the day-to-day work. They know first-hand what is working and what is not, and they see all kinds of ways in which to improve performance, from simple, common-sense ideas for saving time and money, improving quality and safety to entirely new ways of doing operations. We need to strengthen the […]