Lean Thinking - Breakfast Speaker: Ian Marshall
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Lean Thinking - Breakfast Speaker: Ian Marshall

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Lean Thinking - Breakfast Speaker: Ian Marshall Lean Thinking - Breakfast Speaker: Ian Marshall Presentation Transcript

  • LEAN Thinking! Ian Marshall – LEAN Champion Canadian Manufacturers & Exporters www.cme-mec.ca/mb
  • Ian Marshall – Canadian Manufacturers & Exporters Why go LEAN?
  • Five Principles of LEAN Thinking Ian Marshall – Canadian Manufacturers & Exporters
  • Five Principles of LEAN Thinking 1. The only perception of Value that matters… is the perception held by the customer 2. Map the Value Stream – keep it simple & involve those who work the process… help them to see 3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste 4. Let your Customer ‘Pull’ from you what they need when they need it 5. Perfection - pursue perfection… not competitors Jim Womack - Lean ThinkingJim Womack - Lean Thinking Ian Marshall – Canadian Manufacturers & Exporters
  • Five Principles of LEAN Thinking 1. The only perception of Value that matters… is the perception held by the customer 2. Map the Value Stream – keep it simple & involve those who work the process… help them to see 3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste 4. Let your Customer ‘Pull’ from you what they need when they need it 5. Perfection - pursue perfection… not competitors Jim Womack - Lean ThinkingJim Womack - Lean Thinking Ian Marshall – Canadian Manufacturers & Exporters
  • Map the Value Stream Process Steps Cycle Times Issues Root Causes Solutions Ian Marshall – Canadian Manufacturers & Exporters ““Wherever there is a customer, there is always a value stream…Wherever there is a customer, there is always a value stream… your challenge is to see it.”your challenge is to see it.” Jim Womack - Lean ThinkingJim Womack - Lean Thinking
  • Five Principles of LEAN Thinking 1. The only perception of Value that matters… is the perception held by the customer 2. Map the Value Stream – keep it simple & involve those who work the process… help them to see 3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste 4. Let your Customer ‘Pull’ from you what they need when they need it 5. Perfection - pursue perfection… not competitors Jim Womack - Lean ThinkingJim Womack - Lean Thinking Ian Marshall – Canadian Manufacturers & Exporters
  • Ian Marshall – Canadian Manufacturers & Exporters Think of rocks and boulders as “waste” because they slow down the water flow. Lean is focused on eliminating these barriers so that water (or production) can flow smoothly without interruptions. Lean = flow
  • Ian Marshall – Canadian Manufacturers & Exporters Sales Engineering Planning Purchasing Production Information and Material Flow Parts Assembly Paint Finishing Shipping C a s h Q u o t e Information and Material Flow
  • Ian Marshall – Canadian Manufacturers & Exporters What percentage of lead time is Waste?
  • The Seven Wastes *Waste: That which adds cost with no value provided to the customer For ServiceFor Service • Errors in DocumentsErrors in Documents • Transport of DocumentsTransport of Documents • Doing Work Not RequestedDoing Work Not Requested • Waiting for the Next StepWaiting for the Next Step • Process Steps & ApprovalsProcess Steps & Approvals • Unnecessary MotionUnnecessary Motion • Backlog of WorkBacklog of Work Developed by Taiichi Ohno - classic Toyota Seven Wastes For ManufacturingFor Manufacturing • DefectsDefects • TransportationTransportation • OverproductionOverproduction • WaitingWaiting • ProcessingProcessing • MovementMovement • InventoryInventory Product & Process Innovation, Inc. Ian Marshall – Canadian Manufacturers & Exporters
  • Ian Marshall – Canadian Manufacturers & Exporters Obtain docs Prep docs Queue 4 8 12 16 20 24 28 32 36 Selection Com.Assess Letter Sign agrmt.Certificate Obtain docs Prep docs Buffer 4 8 12 16 20 24 Sign agrmt. 4 8 12 Current State 6 Months Future State Long-Term Future State 40% reduction of cycle time 50% reduction of cycle time Screen Visit Screen Visit Assess & Letter Certificate Screen Visit + assess LetterObtain docs Lead Time Reduction
  • Five Principles of LEAN Thinking 1. The only perception of Value that matters… is the perception held by the customer 2. Map the Value Stream – keep it simple & involve those who work the process… help them to see 3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste 4. Let your Customer ‘Pull’ from you what they need when they need it 5. Perfection - pursue perfection… not competitors Jim Womack - Lean ThinkingJim Womack - Lean Thinking Ian Marshall – Canadian Manufacturers & Exporters
  • Service at the touch of a button! Ian Marshall – Canadian Manufacturers & Exporters
  • Materials on site when you need them! Ian Marshall – Canadian Manufacturers & Exporters
  • Five Principles of LEAN Thinking 1. The only perception of Value that matters… is the perception held by the customer 2. Map the Value Stream – keep it simple & involve those who work the process… help them to see 3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste 4. Let your Customer ‘Pull’ from you what they need when they need it 5. Perfection - pursue perfection… not competitors Jim Womack - Lean ThinkingJim Womack - Lean Thinking Ian Marshall – Canadian Manufacturers & Exporters
  • Lean Sensei International The Toyota Way Challenge Kaizen Respect Teamwork Go & See Continuous Improvement The Toyota Way 2001 Respect For People
  • LEAN Definition “LEAN is an Operations’ Strategy with a new set of Values to Engage People in Continuously Improving Safety, Morale, Quality, Cost and Productivity.” Jeffrey Liker, author of The Toyota Way Lean Sensei International
  • Toyota Philosophy… Average person + Standardized work environment + Challenge = Performance Excellence… Ian Marshall – Canadian Manufacturers & Exporters
  • Ian Marshall – Canadian Manufacturers & Exporters
  • Ian Marshall – Canadian Manufacturers & Exporters
  • Ian Marshall – Canadian Manufacturers & Exporters
  • Resources Ian Marshall – Canadian Manufacturers & Exporters
  • www.cme-mec.ca www.lean2015.com www.leansensei.com www.lean.org www.sme.org www.ame.org www.TWI-Institute.com www.superfactory.com www.productivitypress.com Resources - websites David Chao – Lean Sensei International Ian Marshall – Canadian Manufacturers & Exporters
  • Resources - books The Machine that Changed the World – Womack, Jones & Roos Lean Thinking – Womack & Jones The Toyota Way – Liker Toyota Culture – Liker & Hoseus The Toyota Way to Lean Leadership – Liker & Convis Toyota Kata - Rother The High Velocity Edge – Spear Managing to Learn – Shook Understanding A3 Thinking – Sobek & Smalley Leading the Lean Enterprise Transformation – Koenigsaeker David Meier, Jeffrey Liker, Michael Hoseus Ian Marshall – Canadian Manufacturers & Exporters