Austin's Lean Software Community
Toyota pioneered the use of A3 Reports as a way of getting the problem, analysis, corrective actions and action plan on a single sheet of large paper (often using graphics more than words). A3’s have evolved to become Toyota’s standard format for problem solving, proposals, plans and status reviews. As a standard way of communicating, the A3 makes it easier for one to gain understanding and support for new ideas and changes. The A3 helps foster dialogue within an organization around a standard Plan-Do-Check-Act process that clarifies the link between issues and actions.
The discussion will address a little of the history behind the A3, what it is and is not. We will then look at the structure, components and how to use them.
Participants should bring a few example issues so that they can start filling out their own A3.
Bob Wilson started his lean learning working for Toyota at the plant in Georgetown Kentucky. His interest in learning what made Toyota so successful led him to becoming a Kaizen Circle Leader and then a Toyota Certified Instructor to teach others about Toyota’s methodologies.
Bob worked on the implementation of lean methodologies and earned his Six Sigma Black Belt Certification while working with the Ford Motor Company. During his time as head of the Tool and Die Department, quality and downtime issues were reduced by over 70%.
Bob was the Lean Enterprise Manager over five plants with 1500 employees with E-One, a subsidiary of Federal Signal, which manufactures fire trucks and other emergency response vehicles. Through the implementation of Lean Principles, E-One was able to consolidate down to four plants. Bob worked on projects within the business and engineering processes which reduce up front lead times by over 100 days. During his time as Manager of the Aerial Plant, which manufactured all Aerial Fire Trucks and Airport Rescue Fire Fighting (ARFF) trucks, he reduced plant discretionary spending by 40%, increased delivery to 100% on time deliveries from 85% and improved quality from an average of 40 DPU to less than 5 with the first ever zero item ARFF delivery.
Bob invented, developed and patented a wireless andon system used by many companies as they implement lean methodologies. He has grown the business to service companies in many industries from automotive, high tech, medical devices, aerospace and home products. He also continues to teach lean methodologies and helps companies get the most value out of their lean transformations. He continues to work with Toyota’s plants in Indiana and Canada to improve their andon system and response process.
Bob has an undergraduate in Business Administration from Kentucky State University and graduated Summa Cum Laude with his MBA from the University of Florida.