Nestlé Continuous Excellence: Goal Alignment

Nestlé Continuous Excellence
Goal Alignment
Basic Problem Solving “Go-See Think Do and BDA”
Coaching Calibration
Updated 12/28/16
Mike Karpe 2016

Agenda
Review and Changes for 2017
Calibrate to the Coaching Tools
Understand the Deliverables of GSTD
Review Common Mistakes
Go-See Think Do 2
What Is a Coach?
Does Does Not
• Ask open ended questions • Steer team to a solution
• Keep team following the • Actively participate in
tool GSTD/BDA beyond coaching
• Coach each section and not • Take actions from
just at the end GSTD/BDA
• Use evaluation tool as the • Need to have knowledge on
guide the problem
• Challenge root cause
Current GSTD
Assessors
What they are: Advanced Problem Solving Experts able to certify
coaches and conduct official GA calibrations
Process: Conduct calibration, align to expectation of FRM 1299,

conduct a certification through observation.
Current Assessors
Go-See Think Do 4
Changes/Updates
Go-See Think Do 5
BDA / GSTD Has Merged Into One Form
Go-See Think Do 6
Roles and Responsibilities
Team Operator Mechanic GSTD BDA

GSTD BDA Coach Coach
Leader Leader
IR X X X X
(GoSee)
BDA X X
Think X X X X
DO X X X X
Go-See Think Do 7
Sign-off on Assessment Tool
Process Owner
BU Leader
Op’s Manager
Go-See Think Do 8
Focus will be on RTL
The GSTD/BDA should be started immediately
when the problem occurs. Without it we loose the
evidence we can collect during the GEMBA
Go-See Think Do 9
Metrics Reported
 80% of GSTD’s will be launched real time

(within the shift the trigger was met).
 80% of GSTD’s will be operator led
 80% of GSTD’s launched were completed
and turned in
 80% effectiveness of GSTD’s completed
Go-See Think Do 10
Hands On
Coach will provide a GSTD/BDA and their

coaching form for use during calibration
• Calibrate to GA requirements
Discuss Findings with original Coaching
sheet
Go-See Think Do 11
4 Mandatory Deliverables of GSTD/BDA
Results-were they achieved (verification step)

Standardization-new activities captured in a
standard to keep changes in place
Reapplication-Training done with impacted team
and learnings applied to similar processes
throughout the organization
Capability building-team members gained
knowledge of problem solving tools and activities
Go-See Think Do 12
Problem Description
The problem description should be a brief

description of the problem and the trigger /
measure impacted
Go-See Think Do 13
Interim Correction
The interim correction is what you are doing to

continue safe quality production until the
GSTD/BDA is complete
The interim correction is not what you did to fix
what already happened
Action needs to be completed immediately if
possible
Go-See Think Do 14
Understand the Problem
Should be a map of the process including what

happened before and after the location of where
the problem occurred.
The location of the problem should be clearly
marked
Information was gathered through GEMBA
Go-See Think Do 15
Problem Statement
What-derived from the problem description

Where-derived from process flow
When-date and time
Who-person(s) involved in the occurrence
How much/many-number affected, how much
time, $ amount, what is relevant to the problem
Combine into one statement using all the 4W1H
Go-See Think Do 16
Standards Review
There needs to be a physical check of standards

Verification of standards are being followed
happens though Gemba
Verify training (DC or TA’s can do this)
Review standards as a team to see if they are
easy to understand
Verify all equipment is within specification
(maintenance can assist)
Go-See Think Do 17
Location of Failure (BDA)
FLOC number has properly been identified and

recorded on form
Work Order has been completed and number
recorded on form
Go-See Think Do 18
Restoration Activity and Process Adjustments
(BDA)
Form contains all activities and adjustments to

restore operation
Go-See Think Do 19
Replacement Components (BDA)
Failed components are kept, properly stored, and

accessible to the BDA team
Equipment and damage codes have been
properly identified and documented on the form
Go-See Think Do 20
Sketch of Failed Component (BDA)
A diagram of the failed component had been

documented (sketch and/or photo)
Outside forces have been included in diagram
(Air, Flow, Torque…)
Failure identified using arrows, circles…
Go-See Think Do 21
Impact Quantification (BDA)
Total loss has been calculated properly assessing

all loss factors necessary
Go-See Think Do 22
Gap Assessment (BDA)
Gaps have been identified by evaluating

difference between ideal conditions and current
conditions through GEMBA
Go-See Think Do 23
Brainstorming (GSTD Specific)
The team should have the proper resources

needed to conduct this session
The entire team needs to participate in
brainstorming / brainwriting
Go-See Think Do 24
Fishbone
BDA
Basic condition items transferred to fish bone
GSTD
All possible causes should be on diagram
Only crossed off through Gemba
All categories need to be explored or discussed
Circle ideas that can’t be ruled out through Gemba
Go-See Think Do 25
5 Why
First branch of the 5 why is a cut and paste from

the identified items off the fishbone diagram
Should be multiple branches off each 5 why
Each item is verified through Gemba
Root cause has been identified (circled, color
coded…)
Go-See Think Do 26
Action Plan
Action is not to create a standard, rather the

activity you wish to place in a standard
Actions should be detailed and directly linked to
root cause.
CAUTION- Gemba items are not actions
Needs to have one person from the GSTD/BDA
team assigned to each action with a reasonable
date or completion
Status of actions are recorded
Go-See Think Do 27
Verification of GSTD/BDA
Effectiveness
If unsuccessful go back to fishbone / 5why’s or

escalate
Happens after all actions are complete
Documented on GSTD/BDA form that verification
was completed
MANDATORY DELIVERABLE OF PROBLEM
SOLVING
Go-See Think Do 28
Standards Updated / Creation
After verification new/changed activities shall be

placed in a standard to obtain static results
MANDATORY DELIVERABLE OF PROBLEM
SOLVING
Go-See Think Do 29
Knowledge Transfer
All relevant areas have transferred knowledge

Learnings have been escalated for transfer
outside the facility where necessary
Go-See Think Do 30
Problem Solving Team
Involvement / Capability Building
Were all core team members present at each

meeting and involved in all steps
Go-See Think Do 31
General Form Completion
The team has accessed the correct resources to

determining and address root cause creating
sustainable solutions
All actions that have not been closed are
captured on the appropriate OR
Go-See Think Do 32
Common Errors
The interim correction IS NOT what you did to fix
what already happened.
Interim correction IS what you will do to prevent
reoccurrence until GSTD/BDA completion
Go-See Think Do 33
Common Errors
Action items are assigned to ONE TEAM
MEMBER
Ongoing is not an acceptable status
Go-See Think Do 34
Common Errors
Failure to achieve all DELIVERIABLES
Results
Standardization
Reapplication
Capability
Go-See Think Do 35
Most Common Error
Single Most Common Error
Not using the criteria in each section of the

coaching tool to assist in coaching and
scoring the GSTD/BDA
Go-See Think Do 36
Where Can I Find the Form & Assessment Tool
Go-See Think Do 37
After GSTD Completion
Place a copy on board(s) GSTD/BDA impacted
Give the DOR a copy of the GSTD/BDA for final
review
Give either the DOR copy to NCE after review or
provide an additional copy along with the
coaching form for recording and retention.
Go-See Think Do 38

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Nestlé Continuous Excellence

Mike Karpe 2016

Process: Conduct calibration, align to expectation of FRM 1299,

Team Operator Mechanic GSTD BDA

 80% of GSTD’s will be launched real time

Coach will provide a GSTD/BDA and their

Results-were they achieved (verification step)

The problem description should be a brief

The interim correction is what you are doing to

Should be a map of the process including what

What-derived from the problem description

There needs to be a physical check of standards

FLOC number has properly been identified and

Form contains all activities and adjustments to

Failed components are kept, properly stored, and

A diagram of the failed component had been

Total loss has been calculated properly assessing

Gaps have been identified by evaluating

The team should have the proper resources

First branch of the 5 why is a cut and paste from

Action is not to create a standard, rather the

If unsuccessful go back to fishbone / 5why’s or

After verification new/changed activities shall be

All relevant areas have transferred knowledge

Were all core team members present at each

The team has accessed the correct resources to

Not using the criteria in each section of the

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