How Values And Habits Become Process Lean Thinking


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An introduction to Lean\'s 5 S concepts and applications.

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How Values And Habits Become Process Lean Thinking

  1. 1. Company Culture & Lean Thinking How Values & Habits Become Processes
  2. 2. Lean Basics Whenever there is a product for a customer, there is a value stream. The challenge lies in seeing it. Lean is a method of seeing and acting that eliminates ANYTHING that does not deliver value to the customer. Industry averages have shown that companies that adopt Lean practices find that there is 95% waste in their basic office, manufacturing and distribution activities. Does this seem possible?
  3. 3. How to See Waste C omplexity L abor O verproduction S pace E nergy D efects M aterials I nventory T ime T ransportation S afety
  4. 4. Can You Identify Waste? Can You identify Any Closed Mitts items in your Area of work? In Buying? In Ordering-? In basic office functions? In our sales processes? In Distribution? In Customer Contact?
  5. 5. Lean & Core Values Values are invisible. All the Core Values have components that help guide our daily activities. So Values and Culture have components that involve habits or actions.
  6. 6. Culture and Values People are our Core Assets-Capable People Customer Focused Pride What does it mean to be customer focused and to take pride in our capabilities? In it’s most essential meaning, it is aligning our daily work and activities with the goals and needs of our supervisors & customers.
  7. 7. Lean & Company Culture This is where Lean fits in. Lean makes us see how to adapt and change our work habits and activities to be in alignment with those of our customers. Are we aligned by department or really to our customer needs? Do we think inside the box of “department” or in alignment with our customer needs? How can you tell the difference? Being Aligned means considering the implications of your actions on the next step in the Value Stream-Make it a GOOD HANDOFF
  8. 8. The Value Stream The “Value Stream” are all the actions and activities to deliver a company’s products or services to it’s customers. Anything that does not “add value” to the customer is considered wasted energy or activity. Toyota has consistently applied Lean Thinking and Processes and now is the #2 Automotive company in the world and growing! Something must be working!
  9. 9. 1. Where Lean Begins-5 S Sort-Get rid of un-needed Set-in-order-everything in it’s place Shine-daily/weekly schedules Standardize-visual controls Sustain-Continuous improvement Team Leader_________________ Project Name_________________
  10. 10. 5 S Sort Explanation Of The First Pillar - Sort Definition of the First Pillar Only what is needed, only in the amount needed, and only when it is needed. Remove all items from the workplace that are not needed for current production (or clerical) operations. B. The Key to the First Pillar If you Sort, you leave only the bare essentials: When in doubt, throw it out. This principle is a key part of Sort in the context of the five Pillars. C. Why Sort is Important • Problems and annoyances in the work flow are reduced, communication between workers is improved, product quality is increased, and productivity is enhanced. • AREAS TO SORT • _____________________________________ • _____________________________________ • _____________________________________
  11. 11. 5S Set in Order Explanation of the Second Pillar – Set in Order Introduction Sort and Set in Order work best when they are implemented together Definition of the Second Pillar Set in Order means that you arrange needed items so that they are easy to use and label them so that anyone can find them and put them away. Why Set in Order Is Important Setting in Order is important because it eliminates many kinds of waste in production or clerical activities. It is not unusual for a three-hour changeover routine to include 30 minutes of searching. AREAS TO SET IN ORDER _________________________________________________ _________________________________________________ _________________________________________________
  12. 12. 5S Shine Explanation of the Third Pillar – Shine Introduction Definition of the Third Pillar Shine: Keep everything swept and clean Set & Post Daily & Weekly Schedules Why Shine Is Important Another key purpose is to keep everything in top condition so that when someone needs to use something, it is ready to be used AREAS TO SHINE _______________________________________ _______________________________________ _______________________________________
  13. 13. 5 S Standardize Explanation of the Fourth Pillar – Standardize Definition of the Fourth Pillar Why Standardization Is Important Building on this definition, we may define Standardized as the result that exists when the first three pillars-Sort, Set in Order and Shine-are properly maintained • When you think about a city you might say that a well-kept city block is one that has been swept and washed clean of debris and dirt. In the 5S context, a well-kept city block would be one in which results or Sort, Set in Order and Shine are maintained. • AREAS TO STANDARDIZE • ___________________________________________ • ___________________________________________ • ___________________________________________
  14. 14. 5 S Sustain Explanation of the Fifth Pillar - Sustain Definition of the Fifth Pillar The fifth pillar is Sustain. In the context of the five pillars, to Sustain means to make a habit of properly maintaining correct procedures. In your life in general, what do you mean when you talk about sustaining something? Usually, you think of it as drawing on something from inside yourself in order to maintain a course of action-even when forces in your life challenge this effort. AREAS TO SUSTAIN _________________________________________________ _________________________________________________ _________________________________________________