Small Business Seminar:Lean for your small business                              October 26, 2011                The NEW L...
Welcome and Introductions  • NEW Lean Consulting Group    – Provide Lean consulting services    – To community businesses ...
Imagine……….•   Cutting time to process customer requestsby 75%•   Reducing inventory by 75%•   Improving quality by 50% – ...
Lean -  A business system involving all employees   which constantly pursues the elimination of   waste to shorten the le...
Lean Is….                      Lean Is Not             Is                      Is Not• A significant shift in     • A head...
Elements of Lean Thinking Learning to see Focus on process not on people Standard work Continuous improvement One pie...
Lean Toolbox                            5S            A3           Teams                                       Problem    ...
Lean Requires Change• Change is required in  – Thought  – Culture  – Perspective• Change must occur to achieve success.   ...
Change is hard……...But stagnation is fatal.Dr. Peter BishopUniversity of Houston                           9
Implementing ChangeCritical success factors:• Leading• Training• Acting• Sustaining• Plan, Do, Check, Act (PDCA)          ...
Kaizen -  Japanese for improvementor  change for the better.  It refers to a philosophy or practice that  focuses upon con...
Kaizen Events• Cross functional team empowered to make rapid  changes in a process• Targets waste, variability, and non-va...
Continuous Steady Improvementsvia Kaizen EventsI                                                               KaizenM    ...
Key Characteristics of a Lean Team An insatiable drive to increase value through the on-going elimination of waste.       ...
Waste The focus of Lean is…waste elimination.                         15
What is Waste?Anything other than the minimum resources required to add value to an end product or service.               ...
Waste Wheel    VALUE    ADDED    WORK     5%                             Motion        Knowledge                          ...
Waste in the OfficeTypes of Waste              Business Process Waste   Motion                  Walking, routing informati...
Introduction to 5s•   Sieri- Sort•   Seiton- Straighten•   Seiso- Shine•   Seiketsu - Standardize•   Shitsuke- Sustain•   ...
5s• Sort: removing the unnecessary• Straighten: a place for everything• Shine: clean up, fix up• Standardize: everything i...
5SBefore        After                      21
Introduction toValue Stream Mapping (VSM)• A one page visual representation showing the flow of  all processes, informatio...
23
Benefits of LeanGetting the right things to the right place at the right time in the  right quantity to achieve perfect wo...
Who have we helped Change?•   Housing Partnership•   Medical Facility/Retirement Home•   Temperature Controls Solution Pro...
We can help with:•   I need more help, I’m just too busy to keep up.•   I will start fixing it once I find my tool.•   I’m...
Chinese ProverbIf we don’t changewe will end upwhere we are headed…                       26
Are you ready to Change?•   Contact NEW Lean•   Identify your problem/pain (1-3 focus areas)•   Establish goals ex: (reduc...
Contact:• Amy Laukolaukoamy@yahoo.com• Lisa Rothbauer  -             lrothbauer@new.rr.com• Jamie Voster jsvoster@gmail.co...
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  • Small Business Seminar Presentation

    1. 1. Small Business Seminar:Lean for your small business October 26, 2011 The NEW Lean Consulting Group 1
    2. 2. Welcome and Introductions • NEW Lean Consulting Group – Provide Lean consulting services – To community businesses and not for profits with a quality resource for their Lean journey. • Certified Lean Lead Facilitators – Jamie Voster – Lisa Rothbauer – Amy Lauko – Project Lead 2
    3. 3. Imagine……….• Cutting time to process customer requestsby 75%• Reducing inventory by 75%• Improving quality by 50% – 200%• Increasing productivity by 50% – 75%• Reducing clutter• Reducing time it takes to find and do things 3
    4. 4. Lean -  A business system involving all employees which constantly pursues the elimination of waste to shorten the lead time of a process.  Not just for manufacturing! Lean principles can be applied to any business and every process. 4
    5. 5. Lean Is…. Lean Is Not Is Is Not• A significant shift in • A headcount reduction thinking and performance strategy• A long term strategy • Merely a cost reduction• Applicable to any strategy organization and every • A quick, one time fix process • A short term project • Applicable only to• Focused on maximizing manufacturing value – optimizing flow• Culture changing 5
    6. 6. Elements of Lean Thinking Learning to see Focus on process not on people Standard work Continuous improvement One piece flow Error proofing (poka yoke) 6
    7. 7. Lean Toolbox 5S A3 Teams Problem SolvingSetup Reductions TPM Kanban Work CellValue Stream Map Error Proofing 7
    8. 8. Lean Requires Change• Change is required in – Thought – Culture – Perspective• Change must occur to achieve success. 8
    9. 9. Change is hard……...But stagnation is fatal.Dr. Peter BishopUniversity of Houston 9
    10. 10. Implementing ChangeCritical success factors:• Leading• Training• Acting• Sustaining• Plan, Do, Check, Act (PDCA) 10
    11. 11. Kaizen - Japanese for improvementor change for the better. It refers to a philosophy or practice that focuses upon continuous process improvement. 11
    12. 12. Kaizen Events• Cross functional team empowered to make rapid changes in a process• Targets waste, variability, and non-value add activity• All necessary resources are readily available• Look for immediate results that address root cause. 12
    13. 13. Continuous Steady Improvementsvia Kaizen EventsI KaizenM StandardizeP KaizenRO StandardizeV KaizenE StandardizeM KaizenE StartingN ProcessT TIME From “Kaizen”, Masaaki Imai 13
    14. 14. Key Characteristics of a Lean Team An insatiable drive to increase value through the on-going elimination of waste. 14
    15. 15. Waste The focus of Lean is…waste elimination. 15
    16. 16. What is Waste?Anything other than the minimum resources required to add value to an end product or service. 16
    17. 17. Waste Wheel VALUE ADDED WORK 5% Motion Knowledge 1 Waiting 8 Inventory 2 7 3 6 Transport Over- 5 4 Production Over- Correction Processing 17
    18. 18. Waste in the OfficeTypes of Waste Business Process Waste Motion Walking, routing information Waiting Delays and queues, decision makingTransportation Information hand-offs Correction Defects, re-work, incomplete data Processing Unnecessary steps, variation of methodsOverproduction Unnecessary reports and information Inventory A task waiting to be started (inbox) Knowledge Untapped skills and experience, routine non-value adding activities 18
    19. 19. Introduction to 5s• Sieri- Sort• Seiton- Straighten• Seiso- Shine• Seiketsu - Standardize• Shitsuke- Sustain• = 5S 19
    20. 20. 5s• Sort: removing the unnecessary• Straighten: a place for everything• Shine: clean up, fix up• Standardize: everything is consistent• Sustain: maintain, review standards= 5S 20
    21. 21. 5SBefore After 21
    22. 22. Introduction toValue Stream Mapping (VSM)• A one page visual representation showing the flow of all processes, information and material• Current state analysis (snap shot) shows – All current value added and non-value added processes• Future state analysis shows – Improved value added processes and eliminates as much non-value added work as possible• Action plan for target state implementation 22
    23. 23. 23
    24. 24. Benefits of LeanGetting the right things to the right place at the right time in the right quantity to achieve perfect work flow, while minimizing waste and being flexible and able to change.• Reduced waste, costs, and lost opportunities• Increased • Efficiencies • Ability to serve more customers in the same time • Customer satisfaction • Timely customer access to goods and services • Quality • Employee empowerment 24
    25. 25. Who have we helped Change?• Housing Partnership• Medical Facility/Retirement Home• Temperature Controls Solution Provider• Organic American Apparel Company• Collision Repair Shop• Public Library• Counseling Services Company• Homeless Shelter• Home Care Provider 25
    26. 26. We can help with:• I need more help, I’m just too busy to keep up.• I will start fixing it once I find my tool.• I’m overwhelmed and don’t know where to start• I’m too busy to train employees.• There must be an easier way, but how?• Everyone has their own way of getting it done.• I can’t find the part so express order a new one.• There are not enough hours in the day.
    27. 27. Chinese ProverbIf we don’t changewe will end upwhere we are headed… 26
    28. 28. Are you ready to Change?• Contact NEW Lean• Identify your problem/pain (1-3 focus areas)• Establish goals ex: (reduce wait list by 50%)• Develop Plan• Identify Resources• Schedule your Event 27
    29. 29. Contact:• Amy Laukolaukoamy@yahoo.com• Lisa Rothbauer - lrothbauer@new.rr.com• Jamie Voster jsvoster@gmail.com• NEW Lean – newlean.org 29
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