2. The "Leader as Dictator" of the old days tried to tell everyone what to
do.
•No transfer, or Cascade of Responsibility
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The "Leader as Back-Slapper" of the 80s and 90s just set "goals"
(MBO) and let everyone do as they pleased.
•Loss of focus, direction, control
Lean Leadership
3. • The Lean Leader leads a very different
way:
. a s different from the commonly
accepted notion of the "enlightened
modern manager" as it is the old
command and control dictator.
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Lean Leadership
4. Toyota is Toyota.
We can learn from them, but we can't copy them exactly.
How can we operationalize the same principles in our own
companies?
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What can we do??
5. Impact of Lean Transformation at
different organizational levels
A Difficult Struggle at the Mid-management
and First Line Supervisory Level
FRONT LINES
SENIOR
MANAGEMENT
MIDDLE
MANAGEMENT
MUST PROVIDE VISION
AND INCENTIVE
MUST “DO”
MUST LEAD THE ACTUAL
OPERATIONAL CHANGE
Likes
the involvement
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Likes the results
Left with changed,
uncertain role
Role Impact
Muri:
Mura:
Muda:
overburden
variation
waste
6. • Muri - Overburden or unreasonableness to a
person or a machine
• Muda - Waste
Too much overtime!
Stress!
Not enough resources!
• Mura - Instability; Unevenness; Variability;
Inconsistency
- End of month deadlines with much overtime
followed by periods of not enough work!
- All projects scheduled in 1Q with none in 2Q!
- Extensive IT everywhere yet not enough
copy machines!
The Seven
Types of Waste
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System Design to Control the 3
M's
7. Basic problem to solve at different
levels of the enterprise
A Difficult Struggle at the Mid-management
and First Line Supervisory Level
FRONT LINES
SENIOR
MANAGEMENT
MIDDLE
MANAGEMENT
MUST PROVIDE VISION
AND INCENTIVE
MUST “DO”
MUST LEAD THE ACTUAL
OPERATIONAL CHANGE
Likes
the involvement
Wants to be
successful
Role Impact
Problem:
MUDA
Likes the results
Problem:
MURA & MURI
Problem:
MURA & MURA
Muri:
Mura:
Muda:
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overburden
variation
waste
8. PDCA Tools for different levels
Provide the right tool for the right job
FRONT LINES
SENIOR
MANAGEMENT
MIDDLE
MANAGEMENT
MUST PROVIDE VISION
AND INCENTIVE
MUST “DO”
MUST LEAD THE ACTUAL
OPERATIONAL CHANGE Needs the right tools
and skills to be
successful
Likes
the involvement
Role Impact
Problem:
MUDA
PDCA tool:
Policy Management
PDCA tool:
VSM or A3
PDCA tool:
Standardized Work
Likes the results
Problem:
MURA & MURI
Problem:
MURI & MURA
Muri:
Mura:
Muda:
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overburden
variation
waste
9. Mr. Cho of
Toyota:
Three Keys to
Lean Leadership
Go See.
• “Sr. Mgmt. must spend time on the plant floor.”
Ask Why.
• “Use the “Why?” technique daily.”
Show Respect.
• “Respect your people.”
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10. "Data is of course important,
but I place greater emphasis on
facts."
-Taiichi Ohno
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"Go see"
11. Core Toyota View:
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•"You can understand everything
that is really important about a
company by observing from a
good spot on the plant floor."
12. What to look for
- let's make it easy for ourselves.
the scientific
• Plan vs. Actual
• Standardized Work
• PDCA -
method
Tugger
Route
Visually Confirm
on the Shop Floor
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13. Mr. Cho
“Know normal from abnormal…
J
I
D
O
K
A
Best Quality - Lowest Cost - Shortest Lead Time
Operational Stability and Kaizen
J
I
T”
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…right now!”
14. Lean Problem Solving
- at the gemba
- five whys
GEMBA
ENGINEER’S ROOM
DEFECT!!
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TOOLS
15. Respect for People
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Focus on the front line worker
Enable the worker
To work safely
To know his/her customer
To be involved, engaged
To be successful
Worker-out or the Front Lines-back principle
Build your operating system from the operator out
Remove wasteful steps from his work,
Giving it to support people: isolate the waste!
Until nothing is left but value-creating steps.
Don’t waste the operator’s time and effort!
16. • The Lean Leader leads a very different
way:
It is as different from the commonly accepted
notion of the "enlightened modern manager" as it
is the old command and control dictator.
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Lean Leadership
17. And what IS "Leadership"
anyway??
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"The greatest leaders of the 20th century
were Hitler, Stalin and Mao: If that is
"leadership", I want nothing to do with it."
- Peter Drucker
18. Lean Leadership
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Practice of Leadership
vs
Exercise of Power
"I could put a loaded gun to your head."
True leadership exists when people follow when
they don't have t o . "
(James MacGregor Burns)
19. Eiji Toyoda on Leadership
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"The people at the top are just flag-wavers. It
is pure MUDA to wave your flag and have no
one follow you. Waving that flag in a way
that makes people fall in line behind you is
what is important."
The Waste of Empty Flag-Waving
20. The leader's job at Toyota.
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• First, get each person to take initiative
to solve problems and improve his or
her job.
• Second, ensure that each persons'
job is aligned to provide value for the
customer and prosperity for the
company.
21. The Leader's job is to develop
his or her people
SPIRIT of Lean Mentorship:
"If the learner hasn't learned, the teacher hasn't taught"
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22. Extensive Support and Coaching at
the Front Lines of the Organization
Foreman
Group Leaders
Team &
Team Leader
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23. • The Lean Leader leads a very different way:
By setting the vision (more why than how)
with nemawashi dialogue, HK planning
and setting challenging expectations
- at the organizational level
- at the individual level
By building systems and processes that cascade
responsibility
SW, KB, Stop-the-Line as tools that truly empower
HR and HK as broader empowering systems
By influence and persuasion
by example
by being knowledgeable
by getting into the messy details
by coaching and teaching
- through PDCA learning cycles
- through questioning
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Lean Leadership
24. If “managing” is about
thinking...
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“leading” is about getting
other people to think.
-- David Verble
25. If improvement is about taking
responsibility and initiative
Leading is about getting other
people to take initiative
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26. How do you get other people
to think ?
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and take initiative?
28. PDCA Questions
CHECK -
STUDY
ACT PLAN
DO
What: is? is should
not? be?
might
be?
must
be?
How?
What?
Why?
When?
How?
How?
When? Who?
What is?
What is, is not?
Why?
How?
GRASP the SITUATION
What?
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30. What barriers discourage people
from thinking and taking responsibility?
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•You, me or somebody
rushes in to give them the
answer.
•It is more important to give
them the right question than
the right answer.
31. The A3 Thinking Steps
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• What is the problem?
• Who owns the problem?
• What is the root cause of the problem?
• What are some possible countermeasures?
• How will you choose which countermeasure to propose?
• How will you get agreement among everyone concerned?
• What is your implementation plan? What timetable?
• How will you know if your countermeasure works?
• What follow-up issues can you anticipate? What problems may
occur during?
• How will ensure learning and continuous improvement?
32. 49
Title: What you are talking about
Analysis
Plan
Followup
Background
Why you are talking about it.
Current Conditions
Where things stand today.
Show visually – pareto charts, graphs,
drawings, maps, etc.
Target/Goal(s)
The specific outcome required for the
business.
The root cause(s) of the problem.
Choose the simplest problem-solving tool for
this issue
A Gantt chart or facsimile that shows
actions/outcomes, timeline and
responsibilities. May include details on the
specific means of implementation.
Indicators of performance, of progress.
Remaining issues that can be anticipated.
Ensure ongoing P-D-C-A. Yokoten as
needed.
O
w
n
e
r
Proposed Countermeasure(s)
Your proposal to reach the future state, the
target condition.
How your recommended countermeasures
will impact the root cause to change the
current situation and achieve the target.
i
n
i
t
i
a
l
s
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33. Title: Create robust process for translating documents
Plan
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Followup
Background
New domestic plant has massive technical
requirements that must be translated from Japanese
documents. The size and complexity of the project
are creating errors and delays.
Current Conditions
Cost overruns. Delays. Errors. Complexity.
Goal
Reduce errors to manageable rate and simplify
processes.
Reduce cost by 10%.
Analysis
Challenge of translating from Japanese to English.
Complexity and size and amount of documents. Problems
stemming from multiple vendors.
Recommendations
Simplify and improve process performance by
choosing one vendor based on competitive bid
process.
Monitor cost to proposal. Review performance at
end of one-year contract. Put contract up for bid
again if performance goals are not met.
Evaluate current vendor. Identify new vendor
candidates. Develop bid package, distribute, and
choose winning bid.
34. Title: Create robust process for translating documents
Background
Goal
Recommendations
Plan
Followup
New domestic plant has massive technical
requirements that must be translated from Japanese
documents. The size and complexity of the project
are creating errors and delays.
Reduce errors to manageable rate and simplify
processes.
Reduce cost by 10%.
Simplify and improve process performance by
choosing one vendor based on competitive bid
process.
Monitor cost to proposal. Review performance at
end of one-year contract. Put contract up for bid
again if performance goals are not met.
Evaluate current vendor. Identify new vendor
candidates. Develop bid package, distribute, and
choose winning bid.
Current Conditions
Cost overruns. Delays. Errors. Complexity.
How V
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i
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? ???
How Lo11g?
???
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Analysis
Challenge of translating from Japanese to English.
Complexity and size and amount of documents. Problems
stemming from multiple vendors.
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35. PDCA Questions
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• Plan (hypothesis): What and why?
No: "What can be done?"
Yes: "What needs to be done?"
• Plan - Do: When?
No: "How fast can we do it?"
Yes: "When does it need to be done?"
• Check, Reflect: who, why?
No: "What did you do?"
Yes: "Why did you choose to do what you did?"
• Check – Act (Adjust): what, why?
Not just: "Did you get the results?"
But: "What did you learn?"
36. Lean Leadership
• Traditional
“Leadership” as noun: “leaders are born”
• Lean
“Leadership” as verb: “take leadership”
• Traditional
“Leadership” as noun: “leaders are born”
• Lean
“Leadership” as verb: “take leadership”
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37. • How do you “Take leadership”?
Build systems and processes, look for
system/process solutions when things go wrong
Teach, or “Facilitate learning”
Influence right thinking and action
• How do you “Take leadership”?
Build systems and processes, look for
system/process solutions when things go wrong
Teach, or “Facilitate learning”
Influence right thinking and action
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Lean Leadership
38. • How do you “Take leadership”?
Build systems and processes, look for
system/process solutions when things go wrong
No: “My employee did the wrong thing”
Yes: “What went wrong with my process?”
Teach, or “Facilitate learning”
Influence right thinking and action
• How do you “Take leadership”?
Build systems and processes, look for
system/process solutions when things go wrong
No: “My employee did the wrong thing”
Yes: “What went wrong with my process?”
Teach, or “Facilitate learning”
Influence right thinking and action
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Lean Leadership
39. • How do you “Take leadership”?
Build systems and processes, look for
system/process solutions when things go wrong
Teach, or “Facilitate learning”
If the learner hasn’t learned, the teacher hasn’t taught
Operations are a reflection of management
Influence right thinking and action
• How do you “Take leadership”?
Build systems and processes, look for
system/process solutions when things go wrong
Teach, or “Facilitate learning”
If the learner hasn’t learned, the teacher hasn’t taught
Operations are a reflection of management
Influence right thinking and action
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Lean Leadership
40. • How do you “Take leadership”?
Build systems and processes, look for
system/process solutions when things go wrong
Teach, or “Facilitate learning”
Aim to influence right actions and thinking
Model the behavior (right actions)
Look for the thinking behind the actions
• How do you “Take leadership”?
Build systems and processes, look for
system/process solutions when things go wrong
Teach, or “Facilitate learning”
Aim to influence right actions and thinking
Model the behavior (right actions)
Look for the thinking behind the actions
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Lean Leadership
41. The Thinking Production System
Just in Time
“The right part
at the right time
in the right amount”
•Continuous Flow
•Pull System
•Takt Time
Leveled Production
Production Lines
That Stop for
Abnormalities
•A
•Fixed Position Line Stop
•Error Proofing
•Visual Control
•Labor-Machine Efficiency
Standardized Work
Preventative Maintenance; 4S
Robust Products and Processes
Supplier Involvement
Best Quality - Lowest Cost - Short
Through Shortening the Production Flow B
es
st
t Le
ea
ad
d T
Ti
im
me
e
y E
El
li
im
mi
in
na
at
ti
in
ng
g W
Wa
as
st
te
e
J
Ji
id
do
ok
ka
a
“
“B
Bu
ui
il
lt
t-
-i
in
n Q
Qu
ua
al
li
it
ty
y”
”
utomatic Machine Stop
Operational Stability and Kaizen
Getting people
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to think and
take initiative
is the key!
42. Change - the leader's role.
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"John, I can't get my people to do this."
How can you get others to "do this".?
Only one w a y .
43. Where Do You Start - From Top or Bottom?
Change Culture
First
(Conventional way)
Change System
First
(Lean Way)
Lean Enterprise Transformation
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44. Lean Enterprise Transformation
It’s easier to act
your way to a new
way of thinking
than to think your
way to a new way
of acting.
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