Change n n n ISE 311 Individual change

Change n n n ISE 311 Individual change ¨ Ch. 31 – Job Instruction/Training Organizational change ¨ Ch. 32 – Managing Change Monitoring change ¨ Ch. 33 – Job Evaluation (not this time …) 1

Chapter 31 - Job Instruction/Training n Is Training the Solution? ¨ Training is temporary. ¨ Solve health and safety problems with permanent engineering solutions instead. n Training Needs Assessment ¨ Identify drivers of training need. ¨ May be external or internal. ¨ What knowledge and skills will close the gap between actual and desired performance? ISE 311 2

Reasons for Job Training n Static Job and Static Worker ¨ Use training to improve the worker’s job knowledge. ¨ Teach: n n Better methods New skills New techniques for performing familiar tasks Static Job and Changing Worker ¨ Pre-train employees through cross-training. ¨ Train potential employees. ¨ Several workers may have to be trained when a job is created or eliminated. ISE 311 3

Reasons for Job Training (cont. ) n Changing Job and Static Worker ¨ Train worker in new technology. ¨ Have a product designer learn about ergonomics. n Changing Job and Changing Worker ¨ Major changes occur in a job. ¨ Lean production requires skilled, cross-trained workers. ¨ Worker involvement in decisions requires greater education. ISE 311 4

Designing Job Instruction n Specify Instructional Objectives ¨ In n n a well-defined objective: The desired performance is observable. The desired performance is measurable. The conditions of performance are specified. Organize the Message ¨ Planning: n Decide how to communicate (the medium). n Decide on the specific tactics. ¨ Drafting: Use multiple drafts. ¨ Revising: n Perform pilot tests with the target audience. n Revise the material based on the results. ISE 311 5

Media Options n Kinesthetic n n n Audio n n Auditory messages are transitory. Complex information is difficult to communicate The message is paced by the sender at a fixed rate. Visual n n n ISE 311 Learning by doing Results in learning with long retention. Use for highly repetitive psychomotor movements. Remove dangers during practice. Text, representation of the object, or a combination Linear or branching presentation Communicate to individuals or group Ease of modification Distributed or massed practice Location of instruction 6

Message Options n Pictorial Messages ¨ Live demonstrations ¨ Film/video ¨ Still photographs ¨ Still or animated drawings ¨ Color or black and white ¨ Consider image fidelity. n Text Messages ¨ Words: Write so you cannot be misunderstood. ¨ Style: Reduce the complexity of your writing. ¨ Consider using job aids in writing (e. g. spell checker). ¨ Format: Use tabular rather than narrative formats. ISE 311 7

Tactics n Training (memorization) requires ¨ Subject knowledge by the trainer ¨ Knowledge of how to teach by the trainer ¨ Training materials ¨ Training time ¨ A trainee willing and able to learn n Trainer options ¨ “Sit by Nellie”: Observe a fellow worker. ¨ Let the supervisor do the training. ¨ Hire a teacher to train the workers. ¨ Use self-instruction with good materials. ISE 311 8

Tactics (cont. ) n Programmed Learning ¨ Define the exact behavior the trainee will learn to do. ¨ Present the information in small increments. ¨ Allow the trainee to determine the pace. ¨ Give immediate feedback on results to trainee. ¨ Observe trainee behavior and modify program if necessary. n Enhanced Training ¨ Practice makes perfect. ¨ Part-task training focuses on the difficult parts. ¨ Training wheels permit the trainee to learn without injury or damage. ISE 311 9

Tactics (cont. ) n Simulation ¨ Allows the trainee to gain a high level of skill before doing actual work. ¨ Use when the cost of error in real performance is high. ¨ Computerized simulation has become more accessible. ISE 311 10

Evaluation n Purpose ¨ Use evaluation feedback to improve the training process. ¨ Training is a continuous process. n Techniques ¨ Participant satisfaction ¨ Learning outcomes ¨ Attitude changes ¨ Behavior or performance changes ¨ Accomplishment of organizational goals ISE 311 11

Job Aid Design n Considerations ¨ Information readability ¨ Information content ¨ Information organization ¨ Physical handling and environmental factors n Procedural Job Aids ¨ Include assembly instructions, to-do lists, recipes. ¨ Present information in a decision structure table. ¨ Tables permit decisions to be made by experts without time stress. ¨ Expert systems are computerized, complex decision structure tables. ISE 311 12

Job Aid Design n Psychomotor Information ¨ ¨ n Limit Aids (for Inspection) ¨ ¨ ISE 311 Present in pictorial instruction or on video. Use words + pictures and allow for modifications. Have copies at the machine and in the office. Consider computerizing the material. Have experts define what is acceptable or not. Select a range of parts. Arrange the parts in descending quality and mount or photograph. Give a set to each inspector and operator. 13

Challenge of Change n Technological change interacts with social systems. “The bottom line of engineering is implementation. ” “Where you stand depends on where you sit. ” n Improve the odds through … n n ¨ Communication ¨ Teams ISE 311 14

Stages of the Change Process n Frozen: stability ¨ ‘assembly n Unfreeze: rethink goals, consider alternatives ¨ Introduce n line’ production methods cellular manufacturing concepts Move: try new methods; feelings of insecurity ¨ Cross-training, development of work teams, etc. ¨ Unfamiliar skills, new expectations, etc. n Refreeze: “I like it”; “it works” ¨ Teams n ISE 311 coalesce, skills become familiar, etc. Frozen: stability 15

Force Field Analysis ISE 311 16

Area of Freedom The solution space is reduced to the area of freedom by economic, legal, technical, or policy factors. ISE 311 17

Communication n Resistance to change may result from: ¨ Lack of knowledge ¨ Emotions n Communicate: ¨ Why the change is being proposed ¨ What the expected consequences are n ISE 311 Communication improves the solution and acceptance. 18

Teams (Small Groups) n n n ISE 311 Industrial democracy Quality Circles Power sharing 19

Team Composition n ISE 311 People doing the job under consideration Skilled-trades (maintenance) people Staff people (process engineers, health/safety specialists, first-line supervisors) 20

Key Aspects of Successful Teams n n n ISE 311 Management commitment Training Team composition Information sharing Activities and motivation Evaluation 21

Negotiation n ISE 311 Allows people to change their concepts gradually Eliminates clearly unacceptable designs Improves communication within the group 22

Special Case: Quality Circles n n n Facilitator Membership Problem of ¨ Horizontal barrier ¨ Vertical barrier n ISE 311 Projects Other depts. Support groups Staff /Supervisors Line workers 23

Example Quality Circle Project Step 1: Select the project. ¨ Volume switch defects on stereos Step 2: Analyze present conditions ¨ Pareto analysis ¨ Fish diagrams ISE 311 24

Pareto Analysis 1 Switch rotation accounted for 70% of defects. ISE 311 25

Pareto Analysis 2 n ISE 311 Uneven rotation accounted for 87% of rotation defects. 26

Fish Diagram n Possible causes of switch rotation errors. MATERIAL OPERATOR content education 9 mm interval personality judgment knowledge F cover dimension G bearing loose torsion tight setting nut axis hole G axis setting inspection tools G bearing setting Reduce uneven switch rotation F cover setting tool width INSPECTION TOOLS, JIGS ISE 311 27

Example Quality Circle project (cont. ) Step 3: Establish goals. n Reduce rotation defect rate n Develop implementation plan n Selectively attack problems ISE 311 28

Goals and Schedule ISE 311 29

Example Quality Circle Project (cont. ) Step 4: Promote control activities n Monitor with np charts n Meet to determine causes and prevention n Develop checklists n Revise standard procedures ISE 311 30

np Chart ISE 311 31

Results n n n ISE 311 Defect rate reduced from 1. 3% to 0. 3% Annual savings of 400, 000 yen Did not completely eliminate problem 32

Comments n n ISE 311 Great effort to achieve small savings Sophisticated techniques Attitude toward quality problems Communication 33

Proposing Change: Project Management n n n ISE 311 Define project scope. Act as client’s servant. Consult frequently. Use experts. Give the ‘buyer’ a choice. 34

Proposing change: Written proposals n n n ISE 311 Present convincing information. Make an outline. Know your decision maker. Be concise. Use preferred format and style. 35

Written Proposals (cont. ) n n n ISE 311 Include economic information. State assumptions specifically. Make several drafts. Use effective tables and graphs. Proofread. 36

Oral Presentations n n n ISE 311 Have a clear objective. Start and end on time. Reach a conclusion. Stand move around. Allow time for discussion. Use visual aids. 37

Visual Aids n n ISE 311 Overheads Slides/Power. Point Video Flipcharts 38

The Message n n n ISE 311 Organization Tables vs. graphs vs. figures Legibility 39