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Lean Thinking Quality Management ,[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object]
Two Views of an Organization THE WAY WE ARE ORGANISED THE WAY AN ORGANISATION SHOULD WORK SUPPLIERS CUSTOMERS
The Manager’s New Job ,[object Object],[object Object]
Fundamentals of Lean Management System ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Lean Thinking origin ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
What is a Process? Inputs PROCESS Outputs CUSTOMERS Collect   Data Analyze   Data Improve Insight Plan Do Check Act How do we Improve a Process?
The Lean Approach ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Hidden Costs Visible  Costs More Cost saving  (long term)
The Three Voices VOICE OF  THE CUSTOMER VOICE OF  THE PROCESS VOICE OF  THE PEOPLE LEADERSHIP
[object Object],[object Object],[object Object],[object Object],[object Object]
IMPROVEMENT STATEMENT  ,[object Object],VOICE OF THE CUSTOMER ,[object Object],[object Object],[object Object],Three parts of an Improvement System:
Improvement Statement Examples ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],VOICE OF THE CUSTOMER
OPERATIONAL DEFINITIONS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],VOICE OF THE CUSTOMER
THE SEVEN QUESTIONS ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],VOICE OF THE CUSTOMER
The Eighth question ,[object Object],[object Object],VOICE OF THE CUSTOMER ,[object Object],[object Object],[object Object],Gathering their voice:
[object Object],[object Object],[object Object],[object Object]
PROCESS MAPS - FLOWCHARTS ,[object Object],[object Object],[object Object],[object Object],VOICE OF THE PEOPLE
Practical Guidelines for Flowcharting Involve people who do the work. Make sure everyone in the team participates. Keep it simple – use shadow boxes.. Treat as working document – subject to constant change and improvement. Generate lots of objective questions. Discuss with others affected by the process (Customers and Suppliers). VOICE OF THE PEOPLE
The Customer-Supplier Chain S I P O C Measures Measures Process Map Suppliers Inputs Process Outputs Customers Requirements  Requirements  VOICE OF THE PEOPLE
Value Assessment or Stream Mapping Steps that are considered  essential  to produce and deliver the product or service to meet the Customers needs and requirements. The Customers are willing to pay for these steps.  Steps that are not essential to the Value Flow – but which enable it to operate   Steps that are considered  non-essential  to produce and deliver the product or service to meet the Customer’s needs and requirements.  The Customers are not willing to pay for these steps.   VOICE OF THE PEOPLE VALUE ADDED WORK NON-VALUE ADDED WORK VALUE ENABLING WORK
The 7+1 Wastes (TIM WOOD) ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],VOICE OF THE PEOPLE
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Three Approaches – Data Collection ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],VOICE OF THE PROCESS
Why do we need to measure? ,[object Object],[object Object],[object Object],[object Object],[object Object],VOICE OF THE PROCESS
Cause & Effect Root Cause Analysis ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],CONVERGENT DIVERGENT VOICE OF THE PROCESS
Example : Cause & Effect Problem: Eg project does not deliver on budget Possible  causes Possible  causes People Processes Finance Resources Inexperienced Poor communications Late invoicing Cash flow not monitored Change not managed Inefficient Computer network problems VOICE OF THE PROCESS
The Five Whys ,[object Object],[object Object],[object Object],[object Object],[object Object],VOICE OF THE PROCESS
[object Object],[object Object],[object Object],[object Object],[object Object]
Improve  ,[object Object],[object Object],[object Object],[object Object],PLANNING IMPROVEMENT
Selecting Solutions:  Eliminate Low Payoff Solutions Low High Low High Benefit Eliminate all  Low Effort/Low Payoff   and  High Effort/Low Payoff   solutions From further Consideration Effort A payoff Matrix looks at the Relationship of Benefit  And effort to reduce the number  of Solutions to address PLANNING IMPROVEMENT
Concept Selection (Pugh) Matrix + - = + Timeliness Accuracy Customer Requirements  Concept 1 Concept 2 PLANNING IMPROVEMENT ,[object Object],[object Object]
Aligning the Voice of the Process and the Voice of the Customer TIME SERIES OR SEQUENCE The Voice of the Customer The Voice of the Process What was, what is And what will be BAD GOOD PLANNING IMPROVEMENT
[object Object],[object Object],[object Object],[object Object],[object Object],Holding the Gains
Standardization  ,[object Object],[object Object],[object Object],HOLDING GAINS
The Purpose of Standardisation A D S C A P C A S C D D Improvement  Maintenance  Maintenance  There can be no improvement where are there are no standards HOLDING GAINS A P C D Improvement
What are recommendations for formalization  and documentation? ,[object Object],[object Object],[object Object],[object Object],[object Object],HOLDING GAINS
Failure Mode Effect Analysis ,[object Object],HOLDING GAINS
The FMEA Process IDENTIFY FUNCTIONS  IDENTIFY FAILURE MODES IDENTIFY EFFECTS OF  THE FAILURE MODES DETERMINE SEVERITY IDENTIFY POSSIBLE  CAUSES DETERMINE LIKELIHOOD CALCULATE CRITICALITY IDENTIFY DESIGN OR  PROCESS CONTOLS DETERMINE  DETECTABILITY FINAL RISK ASSESSMENT ACTION TO  REDUCE RISK HOLDING GAINS
POKA YOKE ,[object Object],[object Object],HOLDING GAINS
Continuous Improvement -desirability Vs acceptability Acceptable  Acceptable  Acceptable  Not acceptable Most desirable Less desirable Even less desirable HOLDING GAINS
RESULTS IMPROVED LEADERSHIP ENHANCED  CUSTOMER  SATISFACTION VOICE OF  THE CUSTOMER VOICE OF  THE PROCESS VOICE OF  THE PEOPLE
[object Object],IMPROVEMENT !!
Many Thanks………..

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Lean Thinking Baljit

  • 1.
  • 2.
  • 3. Two Views of an Organization THE WAY WE ARE ORGANISED THE WAY AN ORGANISATION SHOULD WORK SUPPLIERS CUSTOMERS
  • 4.
  • 5.
  • 6.
  • 7. What is a Process? Inputs PROCESS Outputs CUSTOMERS Collect Data Analyze Data Improve Insight Plan Do Check Act How do we Improve a Process?
  • 8.
  • 9. The Three Voices VOICE OF THE CUSTOMER VOICE OF THE PROCESS VOICE OF THE PEOPLE LEADERSHIP
  • 10.
  • 11.
  • 12.
  • 13.
  • 14.
  • 15.
  • 16.
  • 17.
  • 18. Practical Guidelines for Flowcharting Involve people who do the work. Make sure everyone in the team participates. Keep it simple – use shadow boxes.. Treat as working document – subject to constant change and improvement. Generate lots of objective questions. Discuss with others affected by the process (Customers and Suppliers). VOICE OF THE PEOPLE
  • 19. The Customer-Supplier Chain S I P O C Measures Measures Process Map Suppliers Inputs Process Outputs Customers Requirements Requirements VOICE OF THE PEOPLE
  • 20. Value Assessment or Stream Mapping Steps that are considered essential to produce and deliver the product or service to meet the Customers needs and requirements. The Customers are willing to pay for these steps. Steps that are not essential to the Value Flow – but which enable it to operate Steps that are considered non-essential to produce and deliver the product or service to meet the Customer’s needs and requirements. The Customers are not willing to pay for these steps. VOICE OF THE PEOPLE VALUE ADDED WORK NON-VALUE ADDED WORK VALUE ENABLING WORK
  • 21.
  • 22.
  • 23.
  • 24.
  • 25.
  • 26. Example : Cause & Effect Problem: Eg project does not deliver on budget Possible causes Possible causes People Processes Finance Resources Inexperienced Poor communications Late invoicing Cash flow not monitored Change not managed Inefficient Computer network problems VOICE OF THE PROCESS
  • 27.
  • 28.
  • 29.
  • 30. Selecting Solutions: Eliminate Low Payoff Solutions Low High Low High Benefit Eliminate all Low Effort/Low Payoff and High Effort/Low Payoff solutions From further Consideration Effort A payoff Matrix looks at the Relationship of Benefit And effort to reduce the number of Solutions to address PLANNING IMPROVEMENT
  • 31.
  • 32. Aligning the Voice of the Process and the Voice of the Customer TIME SERIES OR SEQUENCE The Voice of the Customer The Voice of the Process What was, what is And what will be BAD GOOD PLANNING IMPROVEMENT
  • 33.
  • 34.
  • 35. The Purpose of Standardisation A D S C A P C A S C D D Improvement Maintenance Maintenance There can be no improvement where are there are no standards HOLDING GAINS A P C D Improvement
  • 36.
  • 37.
  • 38. The FMEA Process IDENTIFY FUNCTIONS IDENTIFY FAILURE MODES IDENTIFY EFFECTS OF THE FAILURE MODES DETERMINE SEVERITY IDENTIFY POSSIBLE CAUSES DETERMINE LIKELIHOOD CALCULATE CRITICALITY IDENTIFY DESIGN OR PROCESS CONTOLS DETERMINE DETECTABILITY FINAL RISK ASSESSMENT ACTION TO REDUCE RISK HOLDING GAINS
  • 39.
  • 40. Continuous Improvement -desirability Vs acceptability Acceptable Acceptable Acceptable Not acceptable Most desirable Less desirable Even less desirable HOLDING GAINS
  • 41. RESULTS IMPROVED LEADERSHIP ENHANCED CUSTOMER SATISFACTION VOICE OF THE CUSTOMER VOICE OF THE PROCESS VOICE OF THE PEOPLE
  • 42.

Editor's Notes

  1. FISHBONE OR HERRINGBONE DIAGRAM (ISHIKAWA) PROBLEM-SOLVING TECHNIQUE – MOST LIKELY CAUSES AND WHICH POSSIBILITY TO INVESTIGATE FIRST DATA CAPTURE ESSENTIAL, OF COURSE