050 CPS Dlrs RIW Checklist (Pre Workshop Followup) v4.0

CPS 6 Sigma Rapid Improvement Workshop (RIW)
Worksheet Description
The Prework Checklist is to be reviewed in the 4 weeks prior to the scheduled RIW. This checklist includes a timeline. Items
RIW Prework Checklist
deemed to be irrelevant to the specific RIW may be disregarded.
Assignments from this worksheet are given to the Subteam Leaders by the Team Leader to ensure accountability for
RIW 5-Day Checklist completion of tasks. A complete list of tasks by designated subteam / team assigned can be filtered by Team Assigned to
ensure all tasks are appropriately assigned.
RIW Day 1
RIW Day 2
The RIW Day 1 through RIW Day 5 is a summary of the checklist worksheet. This could be printed prior to the workshop and
RIW Day 3
made available for display in the team workspace throughout the week to ensure RIW progress stays on schedule
RIW Day 4
RIW Day 5
The RIW 30-Day Checklist worksheet provides the details for activities to be completed during the 30-Day Follow-Up phase.
RIW 30-Day Follow-up Checklist
The tasks are listed by weeks and by role and can be filered accordingly. T
The RIW 30-Day Follow-up Checklist - Summary worksheet provide the Team Leader summary list of activities that need to be
RIW 30-Day Follow-Up
performed
Checklistduring
Summary
the 30-Day Follow-Up phase. The Team Leader can use the "tick boxes" to keep track of completed tasks
and deliverables.
CPS for Dealers
6 Sigma Rapid Improvement Workshop (RIW)
Prework Checklist RIW Date: _______ / _______ / _______
Timeline Task # Task Task Description and Key Points Responsible Date Completed
Week 1 1.1 Complete project charter Create project charter from idea submitted. Sponsor
Each RIW has a minimum expectation of

$100,000 in value prop. The sponsor must be
able to estimate the value prop of the RIW at this
Week 1 1.2 Enter financial estimate into charter Sponsor
stage to determine if this is the right project to
pursue, and to enable the Team Leader to
complete the Executive Summary during the RIW.
Work with CPS for Dealers DC to identify a RIW

Coordinator to aid in completing their respective
Week 1 1.3 Select and notify RIW Coordinator Sponsor
prework tasks, as well as support the team during
the actual workshop.
Based on the submitted project idea, create a

message supporting the reason for change, which
Week 1 1.4 Create reason for change Sponsor
will be used throughout the RIW process as the
"elevator speech" on why the change is needed.
Work with the Local Management to ensure that

Assist Local Management in goals, objectives and scope for the RIW are set
Week 1 1.5 Sponsor
establishing RIW focus which are reasonable and follow the PQVC
format.
Establish goals in PQVC format which are bold

Week 1 1.6 Establish RIW focus Local Management
yet attainable.
Locate as close to RIW Site. Put safety first by

considering team members working in the area,
Week 1 1.7 Identify RIW Team Workspace Coordinator
RIW team members, vehicle traffic, noise level,
environmental issues
Work with the Sponsor and Local Management to

determine the date for the five day RIW. The
workshop should occur approximately four weeks
after the prework begins.
Immediate notification required:

CPS for Dealers Deployment Champion must be
notified of scheduled RIW and any changes to the
Pick RIW date and Reserve Room for schedule including cancellations.
Week 1 1.8 Coordinator
Day 1 Core Training
Reserve a room for Day 1 Core training.
Identify RIW Team Workspace. Only if it is
determined a suitable workspace is not available
near the project site then reserve a room for the
ENTIRE week. This room will need whiteboard
space, a projector, telephone, internet connection,
a central conference table and enough chairs to
accommodate the entire team.
Based on the submitted project idea, determine

the Stakeholders (those most likely to be affected
Identify Stakeholders and Process
Week 1 1.9 by the RIW) and the Process Owner's that will be Sponsor
Owners
responsible for sustaining all changes
implemented during the RIW.
File: 386629541.xls Caterpillar: Confidential Green

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Tab: RIW Prework Checklist 05/09/2018
CPS for Dealers
Use the Burning Platform and the RIW focus to

Meet with Process Owner and scope the RIW and discuss any key details /
Week 1 1.10 Stakeholders to discuss scope of concerns that anyone might have. It is critical to Sponsor
project and details have a clearly defined scope to avoid scope creep
and distraction from the true focus of the RIW.
Work with the CPS for Dealers DC to identify a

RIW Coach. The Coach should be selected
Week 1 1.11 Select RIW Coach based on the RIW focus and scope to ensure the Sponsor
best capability building of the team possible
during the RIW.
See the RIW Roles and Responsibilities for

Select Team Leader, Sub Team guidelines on selecting each of these roles.
Week 1 1.12 Local Management
Leaders, and Team Members ALL RIW participants should be at least CPS for
Dealers Yellow Belts.
Make sure all items in proper quantity are in the

RIW kit, ensure all necessary tools to execute
Week 1 1.13 Prepare RIW Kit Coordinator
RIW are available. See website for suggested
content.
Send out the initial communication inviting the

Team Leader, Sub Team Leader, and Team
Members to participate in the workshop. These
Week 1 1.14 Send out RIW invitations communications should be routed through / Coordinator
copied to each person's immediate supervisor.
If any team members are not GBs use this

Week 1 1.15 Train new Green Belts opportunity to train them. This is an opportunity for Sponsor
6 Sigma Green Belts as well as CPS Green Belts.
Contact HR, or local Communication Coordinator

Begin development of Change to begin development of a Change Management
Management Plan Plan that includes communication, learning and
reinforcement.
Communicate to Local Management It is key that the Local Management understands

Week 2 2.1 and Coordinator about RIW area the importance of preparing for the upcoming RIW Sponsor
preparation and scheduling to minimize impact on production.
If a major equipment move is anticipated during

the RIW, Local Management must ensure that the
proper preparation is completed to minimize
Week 2 2.2 Plan / prepare for RIW area moves Local Management
impact, including producing ahead of schedule to
compensate for any downtime during the RIW and
the associated equipment moves.
Inform the area Support Groups of the upcoming

RIW and the possible resources that will need to
Notify Support Groups of anticipated
Week 2 2.3 be on call for the workshop (based on the goals, Sponsor
RIW requirements
objectives, scope, focus, and anticipations of the
Sponsor and Local Management).

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The Sponsor will inform area Support Groups of

the upcoming RIW, including the goals, objectives,
scope, and anticipations of the Sponsor and Local
Meet with Sponsor to discuss
Week 2 2.4 Management such as equipment moves. This Support Groups
resource requirements for RIW
discussion should result in the Support Groups
beginning to line up the proper resources to
provide support DURING THE RIW.
Local Management should be present during the

Schedule Local Management
Week 2 2.5 RIW kickoff, including being prepared to deliver Coordinator
representation for kickoff
the introduction and Burning Platform.
Dates of meetings: Day 2, 3, and 4 of RIW (end

of day)
Purpose of Gate Review: Review the day's

activities (10 minutes) with the key stakeholders,
sponsor, and local Management and get their
Schedule RIW Team Leader
Week 2 2.6 approval of progress and any redirection. Coordinator
Meetings / Gate Reviews
Duration: 20 minutes
Facilitator: Team Leader

Attendees: Sponsor, Local Management, Process
Owner, Stakeholders, Coach.
Dates of meetings: Day 5 of RIW
Purpose of meetings: Review the

accomplishments of the team. Review the before
and after data, Standard Work, layouts, etc. This
meeting is not intended for the leadership to
redirect or push back on what was done during
the week. The purpose of this meeting is for
Week 2 2.7 Schedule Report Out Coordinator
recognition of accomplishments.
Duration: 45 minutes
Facilitator: Team Leader, Sub Team Leader, Team

Members
Attendees: Sponsor, Local Management, Process
Owner, Stakeholders, Coach, CPS for Dealers DC
Lunches, dinners (if applicable) and snacks

should be provided for the team each day during
Determine dietary needs of RIW the RIW (either from the facility's cafeteria
Week 2 2.8 participants and make food services or local restaurants). The dietary needs Coordinator
arrangements of each of the participants should be collected to
ensure all will have food and drink available to
them.
If the Team Leader, Team Members or the Coach

will be traveling from a different location, either
Make necessary travel arrangements arrange or make sure that they arrange for travel
for participants to arrive promptly and will be available during the
duration of the RIW. Care should be taken to
minimize travel expenses.

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The final celebration should be scheduled to

follow the Final Report Out and typically includes
Week 2 2.10 Plan / schedule final celebration Coordinator
a meal. The goal is to recognize the team for their
excellence and dedication during the RIW.
The EHS Professional should:

- Conduct a Safety FMEA Risk Assessment for the
area prior to the RIW (refer to the associated
Safety FMEA Risk Assessment Process & Hazard
Recognition Training)
- Gather Safety Briefing Information from the
facility
Contact Environmental Health and
- Gather Health and Safety policies / rules for the
Safety Professional to conduct the
area
Safety Risk Assessment for the area
Week 3 3.1 - Gather required PPE Sponsor
and provide Health and Safety data
- Collect and analyze injury history / trends for the
to the Coordinator for the Data
area.
Package
- Review all near misses. Investigate if no
documentation exists.
- Provide data for all products in which the team
may be exposed to or use during the workshop
This information is to be forwarded to the

Coordinator to be included in the Data Package.
Each RIW has a minimum expectation of

$100,000 in value prop. The sponsor must be
Review RIW Charter and provide able to estimate the savings of the RIW at this
Week 3 3.2 Process Owner
feedback to Sponsor stage to determine if this is the right project to
pursue, and to enable the Team Leader to
complete the Executive Summary.
Review the charter in eTracker to ensure that

there are no conflicts with the goals, objectives
Review RIW Charter and provide and scope and that there is clarity on the intent
Week 3 3.3 Stakeholders
feedback to Sponsor and focus of the RIW. Provide prompt feedback
to the Sponsor to ensure the charter can be
launched on time .
Contact the Process Owner and Stakeholders to

ensure that they have reviewed the charter and
incorporate any feedback they may have. Launch
Week 3 3.4 Finalize charter Sponsor
the charter once the Process Owner and
Stakeholders are in agreement with the focus and
scope of the RIW.

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CPS for Dealers
The Data Package is a collection of relevant data to be

used during the RIW. Although some data, such as
elemental timings, spaghetti maps, etc., is more
appropriately collected during the workshop, the
collection of other data prior to the workshop allows
the team to place more focus on analysis and
improvement, instead of data collection.
Review the goals of the project to develop a

comprehensive list of relevant data to be included in
the pack. The list below is used to help start the list.
Week 3 3.5 Gather data for Data Package Typical Data Package includes:
Team Leader
- Pre-Delivery Inspection (PDI) Issues
- PFMEA and any other relevant FMEA
- Process Maps, Value Stream Maps (if available)
- Current Standard Work
- Safety trends and history (to be provided by the EHS
Professional)
- Current layout of the area
- Current and future customer demand
- Quality/Scrap reports
- OEE
- EOS Summary (if used at Dealership)
Once the data has been collected from the Team

Leader and Environmental Health and Safety
Week 3 3.6 Send Data Package to Coordinator Team Leader
Professional, forward this data to the Coordinator
for final assembly into the RIW Data Package.
It is essential that the RIW does not contradict the

strategy of the Caterpillar Dealership. Although
this should have been considered throughout the
Confirm RIW aligns with Vision 2020
Week 3 3.7 development of the goals, objectives and scope of Local Management
strategy
the RIW, it is best to revisit the charter one more
time to ensure adherence to the Vision 2020
strategy.
Once the project is launched, the Sponsor meets

Confirm RIW details with Local with the Local Management to ensure full
Week 3 3.8 Sponsor
Management understanding of required preparation and
planning activities.
Contact the required Support Groups to reiterate

Meet with Support Groups to confirm
the goals, objectives and scope of the RIW, and
Week 3 3.9 resource requirements and Sponsor
confirm that the required resources will be
availability
available during the RIW.
The previously contacted Support Groups should

confirm with the Sponsor that their services will be
available for the RIW. It is up to the Support
Confirm resource requirements and
Week 3 3.10 Groups to ensure that arrangements are made for Support Groups
availability with Coordinator
the manpower and other resources required to
provide the proper support AS NEEDED during
the RIW.
During the workshop, certain purchases may be

required as soon as possible, for example, items
Obtain credit card to be used during from a local hardware store. The Coordinator will
Week 3 3.11 RIW for purchases (or other local be in charge of making the trips for the team to Coordinator
purchasing method) obtain anything they might need, therefore, a
credit card for purchasing such items should be in
the possession of the Coordinator.

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During the RIW, team members should be easily

identified. One optional method is to purchases
Develop way to uniquely identify hats for all team members. These hats will act as
team members visual identification of the team during the RIW.
Other visual methods can be used according to
local customs.
Date of meeting: 1 week prior to the RIW
Purpose of meeting: To determine the training

requirements for the RIW team to be presented on
the first day of the RIW.
Duration: 2 Hours
Week 3 3.13 Schedule Week 4 Training Meeting Coordinator
Facilitator: RIW Coach
Attendees: Sponsor, Coach, Team Leader, and
(optional) CPS for Dealers Deployment Champion
Room should have access to whiteboard,

projector, and internet / network access.
Purpose of meeting: To ensure the Team Leader

and Sub Team Leaders understand the scope and
focus of the RIW, as well as each others' roles
Schedule Week 4 Team Leader / Sub and responsibilities.
Team Leader meeting
Duration: 2 Hours

Attendees: Coach, Team Leader, Sub Team
Leaders, and (optional) Sponsor
Purpose of meeting: To ensure the team is clear

on the goals, scope and objectives of the RIW and
their roles and responsibilities for the RIW.
Week 3 3.15 Schedule Week 4 Team Meeting Coordinator
Duration: 1 Hour

Leaders, Team, (optional) Sponsor, Local
Management
Purpose of meeting: For the RIW leadership to

meet one last time prior to the RIW to ensure
everyone is clear on the goals, scope and
objectives of the RIW.
Week 3 3.16 Schedule final Prework meeting Coordinator
Duration: 1 Hour

Attendees: Sponsor, Coordinator, Local
Management, Process Owner, Stakeholders,
Coach, and Team Leader

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CPS for Dealers
Implement Change Management Confirm the development and implementation of a

Plan Change Management Plan.
Package the data collected by the Team Leader

into the Data Package, and forward to the
Send out Data Package to Sponsor, Sponsor, Coach, CPS for Dealers DC, and Team
Coach, and Deployment Champion Leader for their review. This will aid in the
determination of what training must be delivered
on Day 1 of the RIW.
Review the charter and Data Package sent by the

Coordinator and begin to consider what training
Week 4 4.2 Review charter and Data Package should be delivered to the team on Day 1 of the Sponsor
RIW to meet the goals and objectives and build
capability of the team through learning and doing.

Week 4 4.3 Review charter and Data Package should be delivered to the team on Day 1 of the Coach

Week 4 4.4 Review charter and Data Package should be delivered to the team on Day 1 of the CPS Deployment Champion
Select the metrics of the Executive Summary that

Meet with Coach and/or Sponsor to
will be impacted by the RIW and fill in the goals to
Week 4 4.5 complete "Goals" section of Team Leader
achieve (this will be reviewed with the RIW team
Executive Summary
on Day 1)
Purpose of meeting: To determine the training

requirements for the RIW team to be presented on
the first day of the RIW. Prior to the meeting, the
Coach should review the charter and Data
Package, and visit the RIW area if possible to
determine what training he/she would
recommend. This training should be applicable to
the RIW, so that learners can immediately apply
what they learn during the RIW.
Meet with Team Leader, Sponsor, and This meeting should also be used to determine
Week 4 4.6 CPS for Dealers DC to determine who will be delivering the training, i.e. the Team Coach
training requirements for RIW Leader, Coach, etc. Past experience and / or
knowledge of particular subjects should be
considered, however the Team Leader and Sub-
Team Leaders should deliver as much training as
he / she is comfortable with.
Duration: 2 Hours
Facilitator: Coach
Attendees: Sponsor, Coach, Team Leader, and
(optional) CPS for Dealers Deployment Champion

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Once the training materials have been

determined, it is the responsibility of the Team
Leader to review all materials, including any key
points, facilitator notes, etc. - regardless of
Week 4 4.7 Review Training Materials for RIW whether or not the Team Leader will actually be Team Leader
delivering the material. This will familiarize the
Team Leader, enabling him / her to take part in
discussions with confidence. Refer to the Coach
for assistance whenever necessary.
Purpose of meeting: To ensure the Team Leader and

Sub Team Leaders understand the goals, scope and
focus of the RIW, as well as each others' roles and
responsibilities.
This session should be used to train leader and sub-

team leaders of how to calculate TAKT time/cycle time,
spaghetti mapping, develop standard work, 5S,
elemental time, line balance, etc.
Determine sub-team members. Based on the goals

and needs of the RIW determine the Day 1
Meet with Sub Team Leaders and deliverables for each sub-team. Assign a team
member who will be responsible to assure that all
Coach to ensure understanding of
Week 4 4.8 relevant CPS for Dealers Guiding Principals of each Team Leader
RIW objectives and each other’s sub-systems are applied.
roles and responsibilities
This includes directing the Sub Team Leaders to
familiarize themselves with the RIW area and to meet
the employees in the area, asking them questions
about issues they currently have with their areas. This
will begin to establish a relationship with those that will
be affected by the RIW.
Duration: 2 Hours

Attendees: Coach, Team Leader, Sub Team Leaders,
and (optional) Sponsor
Purpose of meeting: To ensure the team is clear

on the goals, scope and objectives of the RIW and
their roles and responsibilities for the RIW.
This is not a substitute for the kickoff or Day 1

training of the RIW. Unless otherwise arranged,
this meeting will mainly discuss the scope at a
high level, with possibly some insight on what
Meet with RIW Team, Coach, and tools / techniques will be utilized during the RIW.
Week 4 4.9 Sponsor to discuss objectives and The main purpose of this meeting is for the Team Team Leader
Day 1 Agenda of RIW to familiarize themselves with each other and to
understand what will be required of them in the
upcoming RIW (i.e. attendance, dress code, etc.).
Duration: 1 Hour

Leaders, Team, (optional) Sponsor, Local
Management

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Purpose of meeting: For the RIW leadership to

meet one last time prior to the RIW to ensure
everyone is clear on the scope and objectives of
the RIW.
Lead Final Prework meeting with
Local Management, Sponsor,
Week 4 4.10 Duration: 1 Hour Team Leader
Process Owner, Coach, and
Coordinator
Attendees: Sponsor, Coordinator, Local
Management, Process Owner, Stakeholders,
Coach, and Team Leader
Sub Team Leaders will familiarize themselves with

the RIW area and meet the employees in the
area. The employees should be asked for issues
Meet with employees in the RIW
and concerns they may have with their area which
Week 4 4.11 affected area to establish relationship Sub Team Leader
may be addressed during the RIW (documented
prior to RIW
on Continuous Improvement Cards). This will
begin to establish a relationship with those that
will be affected by the RIW.
Contact the cafeteria or restaurants that have

been scheduled to provide meals and snacks to
Confirm food and drink arrangements ensure that everything is still on schedule and to
for RIW confirm menus and timing of deliveries for each
day. Revisit the dietary needs of the participants
to make sure everyone will be provided for.
Date of Meeting: 30 days after the final Report

Out for the RIW
Purpose of Meeting: To review the 30 day follow

up list and discuss any open items and what
assistance the Team Leader may need to
accomplish them.
Week 4 4.13 Schedule 30 day follow up meeting Coordinator
Duration: 1 Hour
Facilitator: Project Sponsor

Attendees: Team Leader, Sponsor, Local
Management, Process Owner(s), Stakeholders,
Coach
Meet with the Support Groups one last time to

Ensure Support Groups have
Week 4 4.14 ensure that they are prepared for the RIW with Sponsor
resources finalized
available manpower and resources.
Ensure Support Groups have Meet with the Sponsor to reconfirm the availability
Week 4 4.15 Support Groups
resources finalized of manpower and other resources for the RIW.
Adequate tables and seating for entire team,

assign seating. Arrange area include newspaper,
Week 4 4.16 Prepare RIW Team Workspace Coordinator
agenda, work board, easels and all necessary
supplies

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5-Day Checklist RIW Date: _______ / _______ / _______
Assist the RIW Team with anything needed or

Day 1 1.1 Assist the RIW Team additional resources or materials. Team runner for Coordinator
small items not available in normal supply line.
Opening introductions of Team should include:

- Name
- Role in Caterpillar Dealership
- Role in the RIW
- Number of RIWs completed
- Something unique about yourself
· Inform the team where the restrooms are located

· Inform the team of availability of food and drinks
for day
· Explain the Purpose and Objectives of a 6 Sigma
Day 1 1.2 Conduct Opening Introductions Team Leader
RIW and the Events of the Week
Briefly review the material that was described in

the pre-work package and charter
· 20 minutes maximum
· PowerPoint, video, or physical material
· Use standard forms whenever possible
· Use sketches and drawings
Who Attends: Coach, DC, Sub-Team Leaders, and

Team Members
Teach 6 Sigma RIW Core Training

- Additional material selected that is specific to the
workshop
- Goals and objectives
- Scope of the workshop
Conduct Rapid Improvement
Day 1 1.3 - Take leadership role during group activities Team Leader
Workshop Core Training
- Serve as a knowledge base for others during
training
Who Attends: Sub-Team Leaders, Team Members,

DC, Coach
· Make sure all team members:

- Know the relevant work rules of the area
- Understand any safety-related information for the
Review Rules, Safety Items, and Exit RIW area
Day 1 1.4 Team Leader
Areas - Know where RIW area exits are
- Know who the RIW veterans are on the team
- Know who on the team is most familiar with the
area
Review report guidelines with team:

- 20 minutes maximum
- PowerPoint, video, or physical material
- Use standard forms whenever possible
- Use sketches and drawings
Day 1 1.5 Tour the RIW area Team Leader
Also, highlight material and people flow and
identify specific start/stop points for the RIW.
Who Attends: Team Leader, Team Members,

Coach
Using 5S Scoring Criteria and Audit Sheet,

evaluate the area within the scope of the project.
Day 1 1.6 Conduct initial 5S Audit Sub-Team Leader
-Take photos to document findings. If the photos
are digital, be sure to organize and label.

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Using the Assessment Tool evaluate the area

within the scope of the project.
Day 1 1.7 Safety and Ergonomic Assessment Sub-Team Leader
-Take photos to document findings. If the photos
are digital, be sure to organize and label.
Within the scope of the project determine lay-out,

Day 1 1.8 Measure Area square footage, size of storage area, number of Sub-Team Leader
tubs, inventory and WIP(finished & unfinished).
Develop Value Stream map for the area within

scope (hand-drawn).
Value Stream Mapping helps highlight value-
Day 1 1.9 Value Stream Map Sub-Team Leader
added vs. non-value-added functions and also
helps everyone understand flow and detail of what
the area does.
Sub-teams share with the entire team the

information gathered from the tasks performed
earlier in the day.
Day 1 1.10 Team Meeting Team Leader
The objective of this meeting is to allow all team
members an opportunity to give feedback and
input to the days activities.
The purpose of an Organizational Meeting is to

organize for the week, lay out overall direction of
workshop, set agenda for next day, give team
leader a starting point, and allow team leader and
Day 1 1.11 Conduct an Organizational Meeting sub-leaders to identify knowledge base of team Team Leader
members.
Who Attends: Sub-Team Leaders, Coordinator,

Coach
The Newspaper will determine what will be done,

by whom, and when, track the progress of the
Prepare Newspaper and Agenda team, provides a tool for follow-up, lets the team
for Day 2 see all of its needed activities, provides a “what’s
next” reference point, and helps the team develop
its own detailed action plan.
Complete Baseline column of Executive Summary

Day 2 1.13 Update Executive Summary Team Leader
on pre-selected metrics (Day 1 and Day 2).

Review the schedule for the day with the Team

Day 2 2.2 Review Day 2 Agenda Team Leader
Members.
Review the area layout, flow diagrams, the

number of employees per shift, product demand
by type, Takt Time/Cycle Time Bar chart (if
Day 2 2.3 Review the Data Package with Team available). Team Leader
Review goals, objectives and scope of the RIW.
Address any questions from the team members.
Make sure the team knows what is expected of

Review the 6 Sigma RIW Objectives
Day 2 2.4 them. The objectives should come from the 6 Team Leader
and Team Ground Rules
Sigma RIW package.
Review the CPS for Dealers Guiding Make sure the team knows what is expected of
Day 2 2.5 Principles them. The objectives should come from the 6 Team Leader
and 8 Wastes Sigma RIW package.

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Make sure all team members have clearly defined

Day 2 2.6 Assign Tasks using RIW Newspaper roles, clearly defined assignments, and everyone Team Leader
work towards completion.
Takt Time =
Net Operating Time per Period /
Customer Requirements per Period
Day 2 2.7 Calculate Takt Time Sub-Team Leader
Net Operating Time = Available time per period
less breaks and scheduled downtime
Customer Requirements = Customer requirements
per period (e.g., monthly demand)
Start to 5S the area

· Sort – Segregate and Discharge
· Set – Arrange and Identify
Day 2 2.8 Organize people, material, and tools Sub-Team Leader
· Shine – Clean Daily
· Standardize – Assign Responsibility
· Sustain – Commitment to sustain
Create a Spaghetti Map of the material/information

Day 2 2.9 Create a Material Flow Diagram Sub-Team Leader
flow throughout the area.
The main purpose of the RIW is to eliminate

Day 2 2.10 Identify wastes in the process Sub-Team Leader
waste.
Time observations are done to:

- Understand the current situation
- Observe and document the work process
- Determine the time required to complete the
process
- Observe waste within the process
- If possible videotape the entire process
Day 2 2.11 Make Time Observations Before making time observations, team members Sub-Team Leader
must introduce themselves to production team
members in the area:
- Explain what is being done and why
- Area team members may be asked to follow
consistent sequence of steps for 10-12 cycles
- The data collected must be accurate because the
team will be reliant on the data when eliminating
waste and making improvements
Takt Time/Cycle Time Bar Charts are used to

determine the workload required by each person
Day 2 2.12 Takt Time/Cycle Time Bar Chart in the process, identify unbalanced work Sub-Team Leader
conditions, and determine the number of people
required to perform the process.
Select Wastes to be eliminated:

- List all of the wastes that were identified by the
team
- Rank the wastes according to Impact and
Difficulty
Day 2 2.13 Select Wastes to be eliminated Team Leader
- The wastes that are low Difficulty and high
Impact should be focused on first
- The next wastes to focus on would be low Impact
and low Difficulty
- Use Impact/Difficulty matrix
Use standard 6 Sigma brainstorming technique. If

Brainstorming Solutions for Prioritized
Day 2 2.14 possible the entire team should be included in all Team Leader
Waste
brainstorming sessions.

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Area Update Meeting

· Update all area team members and supervisors
of the 6 Sigma RIW area
· Describe the data that has been collected
· Discuss why it has been collected
· Discuss the Takt Time/Cycle Time Bar Chart of
how the area is currently performing to Takt Time
· Describe what it will be used for during the week
· Quickly review the wastes that have been
identified
· Describe what can be done to eliminate the
Day 2 2.15 Conduct an Area Update Meeting Team Leader
waste
· Ask production team members for their input and
ideas using the CPS Continuous Improvement
cards
· Ask production team members what questions
they have
· Review next steps and what changes production
team members will see the next day
Who Attends: Team Members, Sub-Team

Leaders, DC, Coach
Define and Measure Gate Review:

The Team Leader and Sub-Team Leader attend
and present together while the team continues
working in the workshop area. Present review of
day’s activities for 10 minutes to coach and
Team Leader, Sub-Team
Day 2 2.16 Conduct a Team Leader Meeting persons from management. Area management
Leaders
accepts or redirects team’s activities. This
meeting is not intended for the entire.
Who Attends: Local Management, Stakeholders,

Support Groups, Process Owner, Coach
Give an update to team about Team Leader

meeting, sub-team activities and review workshop
objectives to keep team focused.
Day 2 2.17 Conduct a Team Update Meeting Caution: Although each Sub-Team has their own Team Leader
deliverables the Team Leader must make sure that
they are working together sharing people,
resources, information, ideas, etc.
Day 2 2.18 Review RIW Newspaper Review the day's activities with the Team. Team Leader
Based upon the RIW Newspaper, the team should

Day 2 2.19 Prepare Agenda for Day 3 Team Leader
determine the agenda for Day 3.
Solution selection must be done by mid-morning.

Day 3 3.1 Checkpoint Solution implementation must begin no later than Team Leader
mid-afternoon.


Members.


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CPS for Dealers
The team must first consider waste elimination

and organization of the area and a determination
of additional training required. Then, consider the
location of equipment, machines, desks, etc.,
Day 3 3.5 Design the New Process/Layout necessary in one place. Sub-Team Leader
Next, sketch how the required resources in the
new operation should be laid out. Organize the
area to support the value-added work being
performed.
Assign each production team member a workload

equivalent to Takt Time and create rough draft of
Day 3 3.6 Balance to Takt Time Sub-Team Leader
Takt Time/Cycle Bar Chart showing each
production team member in the area.
Day 3 3.7 Create layout on paper The layout is used to support new work sequence. Sub-Team Leader
Continue to 5S the area

· Sort – Segregate and Discharge
· Set – Arrange and Identify
Day 3 3.8 Organize people, material, and tools Sub-Team Leader
· Shine – Clean Daily
· Standardize – Assign Responsibility
· Sustain – Commitment to sustain
As the team moves closer and closer to true one-

piece flow they will need to implement
Autonomation and error-proofing devices.
Autonomation devices function automatically, but
will stop if an abnormality is detected within the
process. The ability to automatically stop is the key
Day 3 3.9 Identify opportunities for Autonomation Sub-Team Leaders
difference between autonomation and traditional
automation. The Team Leader will need to push
the team to identify opportunities for
Autonomation. These occur only when the labor
time saved is used to perform other value added
work.
Error-proofing is a tool used to ensure there isn’t a

quality problem by eliminating errors from the
operation. Error-proofing devices do not prevent a
Day 3 3.10 Error-proof the operation Sub-Team Leaders
defect from being produced where autonomation
devices detect defects and automatically stop
process operations.
As you look at the new process, consider:

- Flow of material
- Parts and tools presentation
- Physical constraints
- Staging areas
- Future modifications (flexibility)
Simulate the new process (Cardboard
Day 3 3.11 Physical constraints need to be considered: Sub-Team Leader
City)
variable ceiling height, ductwork, load capacity of
floor, conveyor track, hoists, etc.
- Making a full-scale cardboard replica of
equipment that must be moved is a great way to
determine if it will fit without having to move the
actual equipment.

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CPS for Dealers
Iterations describes what works and what doesn’t.

In learning what doesn’t work provides you with
the knowledge that can be used to make
improvements.
Iteration practices include:
Conduct Iterations of improvements if Team Leader and all Sub-
Day 3 3.12 - 5S activities
necessary Team Leaders
- Waste elimination
- Layout and process improvements
- Balancing work
- Autonomation and Error-proofing solutions
- Do them again and again . . .
Use the RIW newspaper to assign team members

to work with maintenance while “big” items are
Day 3 3.13 Assign Tasks using RIW Newspaper Team Leader
being moved to ensure that these items are
moved to the correct locations.
Coordinate (or assign a team member)

Day 3 3.14 Implement the new process Team Leader
communications with maintenance.
Implement Tool and Part Presentation Assign a team member to each workstation/area
techniques team member for the move to the new layout.
Teach area team members the new Ensure that all area team members are aware and
Day 3 3.16 Team
process understand how the new process operates.
Area Update Meeting

identified
Day 3 3.17 Conduct an Area Update Meeting · Describe what can be done to eliminate the Team Leader
waste
· Ask area team members for their input and ideas
using the CPS Continuous Improvement cards
· Ask area team members what questions they
have
· Review next steps and what changes area team
members will see the next day

Leaders, DC, Coach
Analyze and Improve Gate Review

The Team Leader and Sub-Team Leader attend
and present together while the team continues
working in the workshop area. Present review of
day’s activities for 10 minutes to coach and
Team Leader, Sub-Team
Day 3 3.18 Conduct a Team Leader Meeting persons from management. Area management
Leaders
accepts or redirects team’s activities. This meeting
is not intended for the entire team.
Who Attends: Local Management, Stakeholders,

Support Groups, Process Owner, Coach
Give a quick update to team about Team Leader

Day 3 3.19 Conduct a Team Update Meeting meeting or about sub-team activities and review Team Leader
workshop objectives to keep team focused.
Day 3 3.20 Review RIW Newspaper Review the evening's activities with the Team. Team Leader

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CPS for Dealers



Members.

Meet area team members at their work area at the

beginning of the shift and walk area team
members through the new process so they
Train area team members in the new
Day 4 4.4 understand how it should run (use “rough drafts” of Sub-Team Leaders
process
Standard Work Sheet). Thoroughly explain how
the entire new process is planned to work with the
team.
Once the area team members have been taught

Let the area team members run the
Day 4 4.5 the new process, let them run the operation Team
new process
without interference.

Use Time Observation Forms to record area team

members performing new process, make sure all
Verify cycle times of each area team area team members are operating within Takt
Day 4 4.7 Sub-Team Leader
member Time, and identify waste still in the process in the
“Opportunities” column on the Time Observation
Form.
Create new standard work with area team member

input and document the new layout. Ensure all
Day 4 4.8 Create new standard work Sub-Team Leader
updated documents are processed in accordance
with the facility document control procedure.
Review the new process with area Obtain support from all shift area supervisors of 6
supervisors Sigma RIW.
Label locations for everything:

- Standard Work Sheet, posted where area team
member can reference it easily
- Standard work layout, posted where area team
member can reference it easily
- Material presentation/ location (e.g. shadow
Day 4 4.10 5S the area Sub-Team Leader
boards)
5S should be going on throughout the workshop,

but Day 4 of the workshop provides the leader and
the team with the opportunity to visibly review the
workshop area.

These results should have been achieved from the

Day 4 4.12 Collect and post results Sub-Team Leader
RIW.
Give a quick update to team about Team Leader

Day 4 4.13 Conduct a Team Update Meeting meeting or about sub-team activities and review Team Leader
workshop objectives to keep team focused.

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CPS for Dealers
Area Update Meeting

identified
Day 4 4.14 Conduct an Area Update Meeting · Describe what can be done to eliminate the Team Leader
waste
· Ask area team members for their input and ideas
using the CPS Continuous Improvement cards
· Ask area team members what questions they
have
· Review next steps and what changes area team
members will see the next day

Leaders, DC, Coach
Highlight any changes made to the old process.

Lead Local Management on Tour of 6
Day 4 4.15 Sub-Team Leaders
Sigma RIW area
Who Attends: Local Management
Review the Report-Out Outline for guidance on the

Day 4 4.16 Review Report-Out procedure Team
format of the Report-Out Meeting.

Complete the Results section of the Executive

Day 4 4.18 Complete Executive Summary Summary. The Executive Summary will be used in Team Leader
the Final Report-Out, sent to CPS for Dealers DC


Members.
Observe the area team members and the process

Day 5 5.3 Ensure operations are running Team
to ensure that everything is running smoothly.
Using 5S Scoring Criteria and Audit Sheet, re-

evaluate the area within the scope of the project.
Day 5 5.4 Conduct final 5S Audit Sub-Team Leader
Note: Audit should be conducted by the same
person(s) who conducted the initial audit.

Day 5 5.6 Create a 30-Day Follow-Up list List activities not completed. Team Leader
Ensure that all continuous improvement ideas

Report all continuous improvement
generated and implemented are accumulated and
ideas generated and implemented to
Day 5 5.7 delivered to the CPS for Dealers Deployment Team Leader
the CPS for Dealers Deployment
Champion for inclusion in the monthly metrics
Champion
reporting cycle.

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CPS for Dealers
Determine the accomplishments of the RIW team,

summarize results, and celebrate
- Every team member participates
- Emphasize that the Report-Out is an opportunity
to share successes and expose problems
Day 5 5.8 Prepare for Report-Out Presentation Team Leader
- Encourage team to make the report enjoyable
and have fun!
Create agenda list for Report-Out:

- Include topic and team member assigned

Assign Report-Out Tasks using RIW
Day 5 5.9 roles, clearly defined assignments, and everyone Team Leader
Newspaper
Gather material for the Report-Out Create charts and overheads for Report-Out
Presentation Power Point presentation.
Use a Standard Work Combination Sheet to

assure meeting time constraint
Use visuals while practicing the presentation
While practicing the presentation:
- Team stands together along left wall in
presentation order
- Person who presents next should be “on deck”
waiting to go up
Day 5 5.11 Practice giving the presentation Team
- Sub-team leader presents 30-Day Follow-Up list
to discuss what activities related to the workshop
will be completed in near future
- Team Leader thanks the team for its hard work,
resource support people for their help, and
workshop consultant for his or her guidance
- Team leader wraps up the presentation by asking
the audience what questions they have
Give feedback to team members on their Report-

Provide presentation performance
Day 5 5.12 Out presentation and improve the performance Team
feedback
based upon the feedback.
Follow the Report-Out format:

-Introductions
-Starting Point Data
-Before RIW situation
-New Takt time vs. Cycle Time Bar chart
-New Standard Work
-RIW Implemented examples
Day 5 5.13 Conduct the Report-Out Presentation Team
-Executive Summary of RIW results achieved
-RIW 30-Day Follow-Up
-Closing Comments
Who Attends: Support Groups, Stakeholders,

Local Management, Process Owner, DC, Coach
Day 5 5.14 Enjoy the celebration Celebrate the closing of the RIW. Team

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RIW Day 1 / 5-Day Checklist / Tasks and Deliverables
Safety Briefing Introduction / Kick-Off Sponsor Presentation
Ice Breaker Core Training Team Assignments
Stretching Exercise Team Review / Next Day Agenda Update Executive Summary
Stakeholder Review (Optional)
Operating Sub-System Cultural Sub-System Management Sub-System
Tick Box Tick Box Tick Box
Post and Update Newspaper Review Safety Post and Update Newspaper
Provide Area Layout Drawing Action Safety Issues Review Metrics & Charts
Conduct Waste Walk Safety and Ergonomic Assessment Review Quality
Categorize Wastes and Brainstorm Post and Update Newspaper Measure Overall Floor Area
Review Current Process Take Current Pictures Measure Used Floor Area
Review OEE Conduct 5S Audit (original) Count Material Storage
Observe Cycle Times Identify Change Targets Count WIP
Create Spaghetti Maps Daily Report Out Prep 5S Red Tagging & 5S Log
Define Tooling Needs Prepare for 5S Activities
Daily Report Out Prep Daily Report Out Prep

20/28
Tab: RIW Day 1 05/09/2018
Team Meeting Team Assignments Stretching Exercise
Area / Shopfloor Update Team Review / Next Day Agenda Stakeholder Review
Review Newspaper Review Newspaper Review Newspaper
Calculate Cycle Times Safety Issues Review TPM Requirements
Calc Weighted Avg. Cycle Time Gather Baseline Data Package Review Skills Matrix
Calculate Takt Time Take Pictures of 5S Activities Validate Voice of the Customer
Complete Spaghetti Maps Start Final Reportout Plan 5S Sort/Set/Shine
Complete a Material Flow Diagram Daily Report Out Prep Review Andon System
Compile Tooling List Daily Report Out Prep
Create TT/CT Bar Chart
Prepare Cardboard City
Daily Report Out Prep

21/28
Tab: RIW Day 2 05/09/2018
Check Point Area / Shopfloor Update Team Review / Next Day Agenda
Stakeholder Review
Balance to Takt Time Continue Final Reportout Review Metrics Boards
Design New Layout Take Pictures of Changes Finish Skills Matrix
Execute Cardboard City Review 5S Red Tag Log Continue 5S Activities
Develop Improvement Plan Conduct SFMEA Autonomation & Error-Proofing
Pilot Solution Daily Report Out Prep Test Andon System
Write Standard Work Daily Report Out Prep

22/28
Tab: RIW Day 3 05/09/2018
Area / Shopfloor Update Team Review / Next Day Agenda Update Executive Summary
Stakeholder Review
Review New Process changes Take Pictures of Changes Update PFMEA
New area layout New State Data Package Update Metrics Boards
New state Spaghetti Maps Conduct 5S Audit (new) Update Hour by Hour Chart
New state Cycle Times Calculate Improvements Continue 5S Activities
Recalculate OEE Continue Final Reportout Update 5S Check Sheet
Update TT/CT Bar Chart Update SFMEA Re-measure Overall Floor Area
Complete New Standard Work Communication and Recognition Plan Re-measure Used Floor Area
Daily Report Out Prep Daily Report Out Prep Re-count Material Storage
Re-count WIP
Set Minimum/Maximum WIP

23/28
Tab: RIW Day 4 05/09/2018
Training Roster and Surveys Final Report Out Celebration
Practice Final Report Out Practice Final Report Out Clean Report Out Room
Attend Final Report Out Transfer Data Package Confirm 30-Day Action List
Area Tour Practice Final Report Out Practice Final Report Out
Attend Final Report Out Attend Final Report Out

24/28
Tab: RIW Day 5 05/09/2018
CPS for Dealers
30-Day Follow-Up Checklist RIW Date: _______ / _______ / _______
Review Executive Summary value prop

estimated on Day 5 of RIW. Make any
Week 1 1.1 Update Executive Summary adjustments necessary and forward Executive Team Leader
Summary to DC by end of business on Monday
following the RIW.
Date of meeting: end of Week 1
Purpose of meeting: To discuss to ensure that

the 30-Day Follow-Up is going in the correct
direction
Schedule Week 1 Follow-Up Update Duration: 30 minutes

Meeting
Facilitator: Sponsor
Attendees: Stakeholders, Local Management,
Team Leader, and Process Owner

Communicate daily with the Team Leader with

Assist the Team Leader with any
Week 1 1.3 any material or information that may be needed Local Mgmt
resources
to complete the 30-Day Follow-Up
Communicate daily with Team Leader to ensure

Assist Team Leader with obstacles
Week 1 1.4 the vision of the 30-Day Follow-Up is going to Sponsor
that occur
the correct direction
Communicate daily with the Team Leader to
Assist the Team Leader in vision of
Week 1 1.5 meet the goals and objectives of the 30-Day Stakeholders
the 30-Day Follow-Up
Follow-Up
Coordinate actions needed to Determine the resources needed to complete
Week 1 1.6 Team Leader
complete 30-Day Follow-Up actions on the 30-Day Follow-Up
Meeting Type: Week 1 Follow-Up Update
Meeting
Meet with Stakeholders and Local
Week 1 1.7 Management to discuss progress of Duration: 30 minutes Sponsor
Review the goals and objectives of the 30-Day
Follow-Up

direction

Meeting


resources

that occur

Follow-Up
386629541.xls Caterpillar: Confidential Green

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RIW 30-Day Follow-Up Checklist 05/09/2018
CPS for Dealers


Meeting
Follow-Up

direction

Meeting


resources

that occur
Follow-Up

Meeting
Follow-Up

resources

that occur
Week 4 4.3 Prepare Final Status Report Submit to Sponsor Team Leader
Review the Final Status Report sent by the

Week 4 4.4 Review Final Status Report Team Leader and the goals and objectives used Sponsor
in the completion of the 30-Day Follow-Up
Meeting Type: Final Status Meeting
Meet with Stakeholders, Local Duration: 1 hour

Week 4 4.5 Management, and Team Leader to Sponsor
close the 30-Day Follow-Up To communicate the accomplishments of the
RIW team and summarize the results in the
Final Status Report of the 30-Day Follow-Up

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CPS for Dealers
Document all RIW project information required

Complete RIW Close-Out Checklist
Week 4 4.6 by Cat Production System. See Instructions Team Leader
Excel workbook
worksheet in the Excel workbook file.
Close out project charter and Enter the results into 6 Sigma RIW project
transition to Financial Control charter and finalize any further information
When the 30-Day Follow-Up is complete, the

Hand off new RIW process to
Week 4 4.8 results and changes made during the RIW are Sponsor
Process Owner
given to the Process Owner

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30-Day Follow-Up Checklist / Tasks and Deliverables
Team Leader Coordinator Sponsor
Week 1 Week 1 Week 1
Update / Submit Executive Summary Schedule weekly Follow-Up Provide support to Team Leader
meetings as required by Sponsor ensuring closure of 30-Day items
Schedule Green Belt Testing
Schedule Final Status / Control Gate
Ensure closure of 30-day actions
Weeks 2-4 Weeks 2-4 Weeks 2-4
Ensure closure of 30-day actions Schedule weekly Follow-Up Provide support to Team Leader
meetings as required by Sponsor
Conduct 30-Day Final Status and Meet with Stakeholders, Local
Control Gate Review Management, and Team Leaders
to close 30-Day Follow-Up List
Close out project in e-tracker
and transition

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RIW 30-Day Checklist - Summary 05/09/2018

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CPS 6 Sigma Rapid Improvement Workshop (RIW)

Each RIW has a minimum expectation of

Work with CPS for Dealers DC to identify a RIW

Based on the submitted project idea, create a

Work with the Local Management to ensure that

Establish goals in PQVC format which are bold

Locate as close to RIW Site. Put safety first by

Work with the Sponsor and Local Management to

Immediate notification required:

Based on the submitted project idea, determine

File: 386629541.xls Caterpillar: Confidential Green

Use the Burning Platform and the RIW focus to

Work with the CPS for Dealers DC to identify a

See the RIW Roles and Responsibilities for

Make sure all items in proper quantity are in the

Send out the initial communication inviting the

If any team members are not GBs use this

Contact HR, or local Communication Coordinator

Communicate to Local Management It is key that the Local Management understands

If a major equipment move is anticipated during

Inform the area Support Groups of the upcoming

File: 386629541.xls Caterpillar: Confidential Green

The Sponsor will inform area Support Groups of

Local Management should be present during the

Dates of meetings: Day 2, 3, and 4 of RIW (end

Purpose of Gate Review: Review the day's

Facilitator: Team Leader

Dates of meetings: Day 5 of RIW

Purpose of meetings: Review the

Facilitator: Team Leader, Sub Team Leader, Team

Lunches, dinners (if applicable) and snacks

If the Team Leader, Team Members or the Coach

File: 386629541.xls Caterpillar: Confidential Green

The final celebration should be scheduled to

The EHS Professional should:

This information is to be forwarded to the

Each RIW has a minimum expectation of

Review the charter in eTracker to ensure that

Contact the Process Owner and Stakeholders to

File: 386629541.xls Caterpillar: Confidential Green

The Data Package is a collection of relevant data to be

Review the goals of the project to develop a

Once the data has been collected from the Team

It is essential that the RIW does not contradict the

Once the project is launched, the Sponsor meets

Contact the required Support Groups to reiterate

The previously contacted Support Groups should

During the workshop, certain purchases may be

File: 386629541.xls Caterpillar: Confidential Green

During the RIW, team members should be easily

Date of meeting: 1 week prior to the RIW

Purpose of meeting: To determine the training

Room should have access to whiteboard,

Date of meeting: 1 week prior to the RIW

Purpose of meeting: To ensure the Team Leader

Facilitator: Team Leader

Date of meeting: 1 week prior to the RIW

Purpose of meeting: To ensure the team is clear

Facilitator: Team Leader

Date of meeting: 1 week prior to the RIW

Purpose of meeting: For the RIW leadership to

Facilitator: Team Leader

File: 386629541.xls Caterpillar: Confidential Green

Implement Change Management Confirm the development and implementation of a