Lean Inventive Systems Thinking Work Book

Crafitti Consulting Crafting Innovation Together Crafitti Innovation Ignition Workshop Series Sep 26-27, 2008, Bangalore, India Lean Inventive Systems Thinking Practitioner’s Work Book crafting innovation together Delegate Name: Organization: Email-Id: © Crafitti Consulting Private Ltd.

Inventive Thinking ? Defining the Problem (EC3 Framework) crafting innovation together Expand, Collect, Connect Converge © Crafitti Consulting Private Ltd. 2

Expand Nine Windows (or the System Operator Tool) helps you sketch or SUPER- place your problem in SYSTEM a broader space time context. Solutions to problems are often found in the areas adjoining the system in question. SYSTEM crafting innovation together SUB-SYSTEM PAST PRESENT FUTURE © Crafitti Consulting Private Ltd. 3

User Needs The Six Senses Time Purchase Delivery Use Supplements Maintenance Disposal At high Outside Space Home Work Fun On-the move altitudes India Produ Quality Usability Aesthetics Reliability Efficiency Adaptability ctivity Sight Sound Smell Taste Touch crafting innovation together Linguistic Musical Logical Spatial Kinesthetic Inter-personal Needs are perceptional in nature, governed by the five senses (and the sixth sense – intelligence). Intra-personal The needs map gives a quick overview of the how the six senses are gratified by the product at the product-user interfaces – space, time and quality © Crafitti Consulting Private Ltd. 4

System Dependency Matrix Element 1 Element 2 Element 3 Element 4 Element 1 × Element 2   crafting innovation together Element 3  × Element 4  × © Crafitti Consulting Private Ltd. 5

The System Function Map Sore Point crafting innovation together © Crafitti Consulting Private Ltd. 6

Contradictions Improving factors Worsening factors crafting innovation together Weight of moving object Stress or pressure Power Object-generated harmful factors Weight of stationary object Shape Loss of Energy Ease of manufacture Length of moving object Stability of the object's composition Loss of substance Ease of operation Length of stationary object Strength Loss of Information Ease of repair Area of moving object Duration of action of moving object Loss of Time Adaptability or versatility Area of stationary object Duration of action by stationary object Quantity of substance/the matter Device complexity Volume of moving object Temperature Reliability Difficulty of detecting and measuring Volume of stationary object Illumination intensity Measurement accuracy Extent of automation Speed Use of energy by moving object Manufacturing precision Productivity Force (Intensity) Use of energy by stationary object Object-affected harmful factors © Crafitti Consulting Private Ltd. 7

Laws of Evolution Increasing Ideality 4 Shortening of Energy Flow Path Increasing Dynamism 3 2 1 Decreasing human element Increasing Multiplication 0 crafting innovation together Non-uniform evolution of sub- Transition from Macro to Micro systems Transition to Higher Level System Increasing Synchronization © Crafitti Consulting Private Ltd. 8

Ideal Final Result Ideality Quotient = Benefits (Cost + Harmful Effects) What would be the ideal final result? Point of End of Feasibility crafting innovation together Now © Crafitti Consulting Private Ltd. 9

Collect crafting innovation together © Crafitti Consulting Private Ltd. 10

Connect TP 1 TP 2 TP 3 TP 4 TP 5 BP 1 BP 2 BP 3 BP 4 BP 5 TP 1 1 TP 2 1 TP 3 1 TP 4 1 TP 5 1 BP 1 1 crafting innovation together BP 2 1 BP 3 1 BP 4 1 BP 5 1 © Crafitti Consulting Private Ltd. 11

Converge Problems Contradictions 1. 1. 2. 2. Technical 3. 3. crafting innovation together 1. 1. 2. 2. Business 3. 3. © Crafitti Consulting Private Ltd. 12

! Inventive Thinking Searching for novel solutions crafting innovation together © Crafitti Consulting Private Ltd. 13

Inventive Principles - TRIZ 1. Segmentation 20. Skipping 2. Taking Out 21. Blessing in disguise 3. Local Quality 22. Feedback 23. Intermediary 4. Asymmetry 24. Self-service 5. Merging 25. Copying 6. Universality 26. Cheap short-living 7. Nested Doll objects 8. Anti-weight 27. Mechanics substitution 9. Preliminary anti- 28. Pneumatics and action hydraulics 10. Beforehand 29. Flexible shells and Cushioning thin films 11. Equipotentiality 30. Porous materials 12. The other way 31. Colour changes crafting innovation together round 32. Homogeneity 13. Spheroidality 33. Discarding and recovering 14. Dynamics 34. Parameter changes 15. Partial or 35. Phase transitions Excessive Actions 36. Thermal Expansion 16. Another 37. Strong Oxidants dimension 38. Inert atmosphere 17. Mechanical 39. Composite Materials Vibration 18. Periodic Action 19. Continuity of useful action © Crafitti Consulting Private Ltd. 14

Ideal Final Result Ideality Quotient = Benefits (Cost + Harmful Effects) The ideal final result? Ideas beyond the point of feasibility crafting innovation together Now © Crafitti Consulting Private Ltd. 15

Vedic Inventive Principles 1. Observation – Pure observation – Flag 2. Comparison – Suitability – Proportion 3. Addition – One more than before – Sum of properties – Sum of qualities – Qualities of the sum – Encapsulation 4. Subtraction – One less than before crafting innovation together 5. Variation – What’s less? – What’s more? – Cause Movement 6. Rotation – Reverse or exchange – Multiple angles – Destroy and rebuild 7. Division – Complete and incomplete – Part and Whole – Individual and collective © Crafitti Consulting Private Ltd. 16

Laws of Evolution Increasing Ideality 4 Shortening of Energy Flow Path Increasing Dynamism 3 2 1 Decreasing human element Increasing Multiplication 0 crafting innovation together Non-uniform evolution of sub- Transition from Macro to Micro systems Transition to Higher Level System Increasing Synchronization © Crafitti Consulting Private Ltd. 17

The System Function Map 1. Trimming – Eliminate harmful interaction – Eliminate incomplete interaction – Eliminate a field – Eliminate a substance 2. Add – New substance – New Field crafting innovation together 3. Modify – Substance – Field – Incomplete interaction Sore Point © Crafitti Consulting Private Ltd. 18

The Solutions Mind-Map crafting innovation together © Crafitti Consulting Private Ltd. 19

Systems Thinking Putting it all together crafting innovation together © Crafitti Consulting Private Ltd. 20

Connect I1 I2 I3 I4 I5 I6 I7 I8 I9 I10 I1 1 I2 1 I3 1 I4 1 I5 1 I6 1 crafting innovation together I7 1 I8 1 I9 1 I10 1 I: Idea © Crafitti Consulting Private Ltd. 21

Converge - Impact S1 S2 S3 S4 S5 S6 TP 1 TP 2 TP 3 BP 1 crafting innovation together BP 2 BP 3 Clusters of ideas form solutions (S) for Technical Problems (TP) and Business Problems (BP) © Crafitti Consulting Private Ltd. 22

Converge Criteria Identify criteria against which solutions Problems Solutions can be evaluated and prioritized objectively 1. 1. 2. 2. Technical 3. 3. crafting innovation together 1. 1. 2. 2. Business 3. 3. © Crafitti Consulting Private Ltd. 23

Converge - Relative Prioritization The Analytic Hierarchy Process is suitable to be used in multi-criteria decision making scenarios where relative prioritization based on expert judgment is required (due to lack of suitable or relevant absolute measures) Holistic Goal Criteria1 Criteria2 Criteria 3 Criteria Solutions Solutions Solutions Rank Order crafting innovation together Solution Priority © Crafitti Consulting Private Ltd. 24

The Value Stream Map What is the “value” that is being delivered to the customer? What are the activities that are being done to generate this value? crafting innovation together What is the overall “rate of demand”? For each activity note down the What is the average service rate? Cycle Time: How many resources are consumed? Value-added Time: What is the error rate? © Crafitti Consulting Private Ltd. 26

Making it Flow Identify in the VSM: 1. Wait times/ delays 2. Idle Time 3. Changeover time 4. Overload 5. Variable workload/ work rate 6. Excess travel 7. Excess transport 8. Rework 9. Variation from crafting innovation together expectation (better or worse) 10. Over-processing (unnecessary work) 11. Resource crunch 12. Clutter 13. Communication delay •Make changes to the VSM to eliminate the identified problems 14. Cacophony •Create small change experiments to validate © Crafitti Consulting Private Ltd. 27

Enabling Pull Mode Identify in the VSM: 1. The Takt time (rate of demand) 2. The service rate (rate of supply) 3. Minimum batch size Make changes to the VSM: 1. Synchronize with crafting innovation together Takt time 2. Work with smallest possible batch size 3. Mechanisms for demand changes to quickly register across the system © Crafitti Consulting Private Ltd. 28

Building quality in • What are the overall quality goals? • How do they map to specific goals for sub-activities? crafting innovation together • How to ensure that these goals are met without spending extra time on review? Incorporate identified measures into the activities © Crafitti Consulting Private Ltd. 29

How much did we improve? Value Flow Stream •Service Rate •Cycle Time Initial Pull •Resources used Process •Error rate crafting innovation together •Service Rate Built-in •Cycle Time •Resources used quality •Error rate Improved Process © Crafitti Consulting Private Ltd. 30

Takeaways for product innovation life cycle Inventive Thinking Systems Thinking crafting innovation together Lean Thinking © Crafitti Consulting Private Ltd. 31

Crafitti Innovation Ignition Workshop Series Sep 26-27, 2008, Bangalore, India Lean Inventive Systems Thinking Crafitti Consulting Crafting innovation together . . . www.crafitti.com crafting innovation together Navneet Bhushan (navneet.bhushan@crafitti.com) Karthikeyan Iyer (karthikeyan.iyer@crafitti.com) © Crafitti Consulting Private Ltd. 32

Lean Inventive Systems Thinking Work Book

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