Chicken of the Sea Leveraging LeanCor Problem Solving Model


Chicken of the Sea's "Journey to World Class" has yielded significant improvement results in production targets, cost reduction, and efficiency. As part of this leadership training journey, the team is leveraging LeanCor's ORLOE problem-solving model.

Chicken of the Sea (COSI)'s training vision is for its leadership to use the same cultural language and set of tools. The ORLOE model is helping the company achieve this through formalized, cohesive problem solving across the management, supervisor, and front-line leadership teams.

Brian Krafczyk, continuous improvement manager at COSI's Lyons, GA canning plant, has shared the story of COSI's journey for several professional groups including the GAMep sponsored by Georgia Tech. He will also speak at the September 2018 Alchemy Edge Conference.

COSI keeps continuous improvement visual in its "War Room" (pictured).

About LeanCor's ORLOE Problem-Solving Model

It is based on five phases of activity, with each phase divided into Purpose, Tollgate Questions, and Processes and Tools. The five phases of activity are as follows:

1. Operate: Do the work and identify the problem.

Tools: Voice of Customer, CTQ Checklist, Team Member Standard Work, Visual Management, Run Charts, Scoreboards, Leader Standard Work

2. Review: Define the problem and document the current state.

Tools: Go See Management, A3O (A3 ORLOE Problem Solving Model ), Process Map, Swim Lane Map, Current State Value Stream Map.

3. Learn: Determine the root cause.

Tools: Pareto – Critical Few, Brainstorming, Cause & Effect, 5 Why Analysis.

4. Optimize: Identify solutions.

Tools: Future State Improvement Tools, Velocity – One Piece Flow, Pull Systems , Future State Maps & Gap Analysis, XY Matrix for Prioritization, 5S, Leveled Flow

5. Execute: Implement and sustain the solutions.

Tools: Implementation Plan, Timeline, FMEA, Dashboards, Communication Plan, Review Process.

A continuous improvement culture is where people are problem solving at every opportunity. ORLOE was developed to help reach this ideal state. ORLOE provides more descriptive, straight forward, “how to” instructions for effective problem solving. The “Operate” phase provides the minimum things that must be in place for team members to expose problems and be connected to the business. These things include voice of customer, standard work, and visibility to the plan vs. actual state.

Team members can use ORLOE to stop at every problem, use the tools available to dig down to the root cause of the problem, make improvements to eliminate that root cause, and then put controls in place to make sure the process is actually improved and then sustained.

This is the goal of a lean organization; to make small, incremental improvements daily in the need to seek perfection.


Posted by LeanCor Training and Education

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LeanCor Training and Education delivers proven methodologies for individuals and groups to conveniently advance themselves and their organizations. With public and private offerings for the associate to executive levels, our curriculum and stories are rooted in our team’s collective operational and corporate experience. Training can be delivered in online, virtual, or classroom settings.

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