SlideShare a Scribd company logo
1 of 29
Lean Transformation A Journey Anand Subramaniam
[object Object],[object Object]
Origins of Lean ,[object Object],[object Object],[object Object]
Basis of Lean Thinking ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Lean Principles ,[object Object],[object Object],[object Object],[object Object],[object Object],Control Measure Analyse Improve
Note.. ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Challenges ,[object Object],[object Object],[object Object],[object Object],[object Object]
Internal Challenges Gap between enterprise resource planning (ERP) and factory floor Incompatible and Inconsistent systems Lack of timely information to make informed decisions Lack of strategy to unify  information across manufacturing Lack of funds and/or  lack of perceived value
Best in Class – Strategic Actions Improve processes that manage the flow of material and information Lean Initiative Optimise performance at Individual plants and factories Drive standards and consistency Across Global manufacturing networks Improve Sales and Operations Planning Processes
Improvements from Lean Implementation Adapted from: National Productivity Review, Industry Week, Deltapoint Actuals Total Cycle Time Revenues Inventories Invisible Inventories Blue-Collar Productivity White-Collar Productivity Availability  Scrap Delivery Lead Times Time-to-Market Return-on-Assets 20 40 60 80 100 Ranges in % Improvement Best Practices from Actual Cases
Lean Transformation – Implementation Implementation  What are the key lean principles and practices? How do I transform my enterprise to lean? How do I assess my progress? Process / Checklist Enterprise Level Roadmap Enterprise Transition to Lean  Lean Enterprise Self Assessment Tool
Lean Transformation - Enterprise Approach Information Technology Certified Suppliers Uncertified Suppliers Warehouse Sales & Marketing Warehouse Customers Customer Service Accounting Engineering Human Resources Factory
Enterprise Level Roadmap – High Level Entry / Re-entry Cycle Adopt Lean Paradigm Decision to pursue Enterprise Transformation Enterprise Strategic Planning Long Term Cycle Focus on the Value Stream Develop Lean Structure & Behavior Create & Refine Transformation Plan Focus on Continuous Improvement Implement Lean Initiatives Initial Lean Vision Lean Vision Lean Transformation Framework Short Term Cycle Detailed Corrective Action Indicators Outcomes on Enterprise Metrics Environmental Corrective Action Indicators Enterprise Level Transformation Plan + Source: MIT –  Lean Aerospace Initiative Lean Impact
Enterprise Level Roadmap – Detailed Scan the environment Segment the market Define leadership requirements Create leadership structures Define policies, objectives, targets and budgets Communicate! Communicate! Communicate! Play catchball with deployment teams Play catchball with action teams Use reliable, scientific methods at all levels Discover/correct  performance variances Perform corporate diagnosis with top Champions Assess/analyse performance Capture learning and make it  replicable Re-vision your strategy -- again Renew your business – in real time Use advanced planning methods Celebrate Success! Mission Statement Values  Statement Vision Statement P/O Matrices Focus Team Charter Kickoff Promotion P/O Matrices Deploy- ment  Plans P/O Matrices Action  Plans Plan Summary CEDAC P/O Matrix Phase II:  Pilot Phase I:  Plan Phase III:  Deploy Phase IV:  Integrate Phase V:  Excel business renewal strategy re-vision vision deployment implementation/adherence strategy re-vision Create mission; establish values Envision  the future Study Missions Market Studies Product/ Market Matrix Technology Roadmaps Corporate Diagnosis Develop- ment Plan Relation- Ship Map Organi- graph Target/ means Analysis Finalise policies and budgets Target/ Means Analysis Target/ Means Analysis CEDAC JIT TPM CE Newsletter Website Progress Tables Site Visits CEDAC 5 Minute Meetings Weekly Meetings Monthly Meetings Study Missions Creative Thinking Bottom up Planning Strategic  Scenarios Game Theoretic Models analysis and reflection business renewal    2003 Productivity, Inc.  adC IP0201wc
Example - Enterprise Level Roadmap Source: Productivity Inc.
Benefits of  Enterprise Level Roadmap   ,[object Object],[object Object],[object Object],[object Object],[object Object]
Enterprise Transition to Lean Begins with a description of a Top Level Flow of primary activities referred to as “The Roadmap” Then, provides descriptions of key tasks required within each primary activity Finally, leads discussion of issues, enablers, barriers, case studies & reference material relevant to each task in a common structured framework ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Source: MIT –  Lean Aerospace Initiative
Lean  Enterprise – Self Assessment Source: MIT –  Lean Aerospace Initiative Why Communicate “lean” enterprise-wide What A “lean” vision How Learn from successful “ lean” implementations Who The Enterprise Leader When First step Where Enterprise-wide Information Technology Certified Suppliers Uncertified Suppliers Warehouse Sales & Marketing Warehouse Customers Customer Service Accounting Engineering Human Resources Factory
Checklist, Process & Procedure ,[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],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Example – “Lean Structure ”  ,[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]
Example - “Change - Checklist”
Example - “Convey Need”   ,[object Object],[object Object],[object Object],[object Object],Why Communicate “lean” enterprise-wide What A “lean” vision How Learn from successful “ lean” implementations Who The Enterprise Leader When First step Where Enterprise-wide
Example - “Implement Lean”   ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Level Sort Simplify Shine Standardise Sustain Baseline  0 Unsafe items in work  area. Placement of items  causes unsafe  conditions. Spills, waste, trash, etc.  produce unsafe  conditions. No methods or  procedures documented. No routine  review/correction of  unsafe conditions. Beginner  1 Needed and un-needed  items found in work area. Needed and un-needed  items are placed  randomly throughout the  workplace. Work area and machines  are not cleaned on a  regular basis. Methods of work not  completely documented. Occasional, unscheduled  5S activity. Basic  2 Needed /un-needed  items separated, un- needed tagged. Needed items stored in  an organised manner. Area and equipment  cleaned daily. Methods of work  documented but not  consistently used. 5S activities conducted  on regular basis. Visual  3 Red tag area created, all  un-needed items  removed. Needed items have  dedicated positions  which are clearly  indicated. Standard work layout  posted and maintained. Methods of work posted  and consistently used by  some cell team  members. 5S assessment  conducted occasionally  and results posted. Systematic  4 List of needed items  developed, maintained,  posted. Needed items can be  retrieved within (cell  target) seconds and (cell  target) number of steps. Daily inspections of plant  and area occurs. Methods of work  consistently used by all  cell team members. 5S assessment  conducted on a regular  basis and recurring  problems are identified. Preventive  5 Un-needed items are not  allowed in area. Method for  adding/deleting  indicators for needed  items Root cause sources of  dirt, grease & spillage  have been eliminated. Methods of work are  regularly reviewed and  improved. Root causes of problems  revealed by 5S  assessment are  identified and eliminated.
Example - Value Stream Map
Lean Building Blocks Value Stream Mapping Continuous Improvement Performance Measurement Performance Management Quick Changeover Standardised Work Batch Reduction Teams Quality at Source 5S System Visual Plant Layout POUS Cellular/Flow Pull/Kanban TPM POUS – point of use storage   Source: Techhelp
Waste Elimination Source: John Willey & Sons -  2009 97% NVA 3% VA Most Process Improvement  Teams Attack this . . . . . . Achieve this 97% NVA Typical Value Stream Ratio Value-Added (VA) to Non-Value-Added Activity (NVA) . .and Ignore this Source: C. Fiore;   Lean Strategies for  Product Development ,  ASQ, 2003
Reference - Lean ,[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]

More Related Content

What's hot

Value Stream Mapping Overview Update
Value Stream Mapping Overview UpdateValue Stream Mapping Overview Update
Value Stream Mapping Overview Updatejheaton418
 
We've Had it All Wrong: Manage Processes, Not people
We've Had it All Wrong: Manage Processes, Not peopleWe've Had it All Wrong: Manage Processes, Not people
We've Had it All Wrong: Manage Processes, Not peopleTKMG, Inc.
 
Types of waste - lean Concept Krishna Heda
Types of waste - lean Concept Krishna HedaTypes of waste - lean Concept Krishna Heda
Types of waste - lean Concept Krishna Hedakrishnaheda
 
Sales & Operations Planning Process
Sales & Operations Planning ProcessSales & Operations Planning Process
Sales & Operations Planning ProcessHarshal Badgujar
 
Principles of Kanban - November 2016
Principles of Kanban - November 2016Principles of Kanban - November 2016
Principles of Kanban - November 2016W3 Group Canada Inc.
 
UCSD Class: Lean Office
UCSD Class: Lean OfficeUCSD Class: Lean Office
UCSD Class: Lean OfficeTKMG, Inc.
 
Value Stream Mapping: What to Do Before You Dive In
Value Stream Mapping: What to Do Before You Dive InValue Stream Mapping: What to Do Before You Dive In
Value Stream Mapping: What to Do Before You Dive InTKMG, Inc.
 
Kaizen Events Blitz & Lean Projects
Kaizen Events   Blitz  & Lean ProjectsKaizen Events   Blitz  & Lean Projects
Kaizen Events Blitz & Lean ProjectsAnand Subramaniam
 
Value stream mapping ppt
Value stream mapping pptValue stream mapping ppt
Value stream mapping pptNaik Devang
 
8 WASTES IN LEAN MANUFACUTING & OVERVIEW OF VSM
8 WASTES IN LEAN MANUFACUTING & OVERVIEW OF VSM8 WASTES IN LEAN MANUFACUTING & OVERVIEW OF VSM
8 WASTES IN LEAN MANUFACUTING & OVERVIEW OF VSMSedhuSiddarth
 
Advanced Lean Strategies for Office & Service Environments
Advanced Lean Strategies for Office & Service Environments Advanced Lean Strategies for Office & Service Environments
Advanced Lean Strategies for Office & Service Environments TKMG, Inc.
 
Visual management controls systems techniques
Visual management controls systems techniquesVisual management controls systems techniques
Visual management controls systems techniquesKobi Vider
 

What's hot (20)

Lean transformation
Lean transformationLean transformation
Lean transformation
 
Value Stream Mapping Overview Update
Value Stream Mapping Overview UpdateValue Stream Mapping Overview Update
Value Stream Mapping Overview Update
 
Kanban Pull System
Kanban Pull SystemKanban Pull System
Kanban Pull System
 
Introduction To Lean
Introduction To LeanIntroduction To Lean
Introduction To Lean
 
We've Had it All Wrong: Manage Processes, Not people
We've Had it All Wrong: Manage Processes, Not peopleWe've Had it All Wrong: Manage Processes, Not people
We've Had it All Wrong: Manage Processes, Not people
 
Types of waste - lean Concept Krishna Heda
Types of waste - lean Concept Krishna HedaTypes of waste - lean Concept Krishna Heda
Types of waste - lean Concept Krishna Heda
 
Sales & Operations Planning Process
Sales & Operations Planning ProcessSales & Operations Planning Process
Sales & Operations Planning Process
 
Principles of Kanban - November 2016
Principles of Kanban - November 2016Principles of Kanban - November 2016
Principles of Kanban - November 2016
 
UCSD Class: Lean Office
UCSD Class: Lean OfficeUCSD Class: Lean Office
UCSD Class: Lean Office
 
Value Stream Mapping: What to Do Before You Dive In
Value Stream Mapping: What to Do Before You Dive InValue Stream Mapping: What to Do Before You Dive In
Value Stream Mapping: What to Do Before You Dive In
 
Lean basics
Lean basicsLean basics
Lean basics
 
Kaizen Events Blitz & Lean Projects
Kaizen Events   Blitz  & Lean ProjectsKaizen Events   Blitz  & Lean Projects
Kaizen Events Blitz & Lean Projects
 
Value stream mapping ppt
Value stream mapping pptValue stream mapping ppt
Value stream mapping ppt
 
Lean thinking
Lean thinkingLean thinking
Lean thinking
 
8 WASTES IN LEAN MANUFACUTING & OVERVIEW OF VSM
8 WASTES IN LEAN MANUFACUTING & OVERVIEW OF VSM8 WASTES IN LEAN MANUFACUTING & OVERVIEW OF VSM
8 WASTES IN LEAN MANUFACUTING & OVERVIEW OF VSM
 
Advanced Lean Strategies for Office & Service Environments
Advanced Lean Strategies for Office & Service Environments Advanced Lean Strategies for Office & Service Environments
Advanced Lean Strategies for Office & Service Environments
 
Lean Management
Lean ManagementLean Management
Lean Management
 
Lean Tools
Lean ToolsLean Tools
Lean Tools
 
Fundamentals of Lean
Fundamentals of LeanFundamentals of Lean
Fundamentals of Lean
 
Visual management controls systems techniques
Visual management controls systems techniquesVisual management controls systems techniques
Visual management controls systems techniques
 

Viewers also liked (20)

5 S – Office Audit
5 S – Office Audit5 S – Office Audit
5 S – Office Audit
 
Your Organisation
Your OrganisationYour Organisation
Your Organisation
 
CTQ Matrix
CTQ MatrixCTQ Matrix
CTQ Matrix
 
Customer Service Strategy & Customer Experience
Customer Service Strategy & Customer ExperienceCustomer Service Strategy & Customer Experience
Customer Service Strategy & Customer Experience
 
Cause & Effect
Cause & EffectCause & Effect
Cause & Effect
 
Erp (Re) Implementation
Erp (Re) ImplementationErp (Re) Implementation
Erp (Re) Implementation
 
Design For Six Sigma
Design For Six SigmaDesign For Six Sigma
Design For Six Sigma
 
Service Delivery & Support
Service Delivery & SupportService Delivery & Support
Service Delivery & Support
 
Software Development
Software DevelopmentSoftware Development
Software Development
 
CMMI & Six Sigma Integration
CMMI & Six Sigma IntegrationCMMI & Six Sigma Integration
CMMI & Six Sigma Integration
 
Performance Improvement Culture
Performance Improvement CulturePerformance Improvement Culture
Performance Improvement Culture
 
Solving Client Issues
Solving Client IssuesSolving Client Issues
Solving Client Issues
 
Link (Non)Financial To Supply Chain Performance Metrics
Link (Non)Financial To Supply Chain Performance MetricsLink (Non)Financial To Supply Chain Performance Metrics
Link (Non)Financial To Supply Chain Performance Metrics
 
Six Sigma Lean (SSL)
Six Sigma Lean (SSL)Six Sigma Lean (SSL)
Six Sigma Lean (SSL)
 
Defects Vs. Errors
Defects Vs. ErrorsDefects Vs. Errors
Defects Vs. Errors
 
Project Closure Report
Project Closure ReportProject Closure Report
Project Closure Report
 
Project Initiation Checklist
Project Initiation ChecklistProject Initiation Checklist
Project Initiation Checklist
 
Business Plan
Business PlanBusiness Plan
Business Plan
 
Innovation
InnovationInnovation
Innovation
 
Bottom Line Improvement
Bottom Line ImprovementBottom Line Improvement
Bottom Line Improvement
 

Similar to Lean Transformation ~ A Journey

Developing A Continuous Improvement Environment August 2009
Developing A Continuous Improvement Environment   August 2009Developing A Continuous Improvement Environment   August 2009
Developing A Continuous Improvement Environment August 2009Harvey_Schiller
 
Lean Fundamentals And Line Design 06 04 01
Lean  Fundamentals And  Line  Design 06 04 01Lean  Fundamentals And  Line  Design 06 04 01
Lean Fundamentals And Line Design 06 04 01Dan Junkins
 
RDrew Six Sigma Overview
RDrew Six Sigma OverviewRDrew Six Sigma Overview
RDrew Six Sigma OverviewRon Drew
 
00 Vital Links Lean Six Sigma Change Acceleration 38 Pgs
00 Vital Links Lean Six Sigma Change Acceleration 38 Pgs00 Vital Links Lean Six Sigma Change Acceleration 38 Pgs
00 Vital Links Lean Six Sigma Change Acceleration 38 Pgsfreelean
 
Implementing Balance Scorecard
Implementing Balance ScorecardImplementing Balance Scorecard
Implementing Balance ScorecardAnand Subramaniam
 
Estimating your Process Projects presented at FSOkx BPM Forum
Estimating your Process Projects presented at FSOkx BPM ForumEstimating your Process Projects presented at FSOkx BPM Forum
Estimating your Process Projects presented at FSOkx BPM ForumProlifics
 
Dennis Stevens - Using Agile and Lean to Lead Business Transformation
Dennis Stevens - Using Agile and Lean to Lead Business TransformationDennis Stevens - Using Agile and Lean to Lead Business Transformation
Dennis Stevens - Using Agile and Lean to Lead Business TransformationSFA
 
Lss pharma presentation2-2006
Lss pharma presentation2-2006Lss pharma presentation2-2006
Lss pharma presentation2-2006Omnex Inc.
 
Suaju Company Presentation
Suaju Company PresentationSuaju Company Presentation
Suaju Company PresentationSuaju Ltd
 
Business Agility And Software Development Alan Chedalawada
Business Agility And Software Development   Alan ChedalawadaBusiness Agility And Software Development   Alan Chedalawada
Business Agility And Software Development Alan ChedalawadaValtech UK
 
How To Achieve Process Transformation In Any Organization PowerPoint Presenta...
How To Achieve Process Transformation In Any Organization PowerPoint Presenta...How To Achieve Process Transformation In Any Organization PowerPoint Presenta...
How To Achieve Process Transformation In Any Organization PowerPoint Presenta...SlideTeam
 
Role of the cio in the digital age
Role of the cio in the digital age Role of the cio in the digital age
Role of the cio in the digital age Thanh Hoang Lam
 
Awareness To Lean & 7 Qc Tools
Awareness To Lean & 7 Qc ToolsAwareness To Lean & 7 Qc Tools
Awareness To Lean & 7 Qc ToolsNilesh Sawant
 
Competing On Resources Balance Scorecard
Competing On Resources  Balance ScorecardCompeting On Resources  Balance Scorecard
Competing On Resources Balance Scorecardvinod63
 
Business Process Improvement
Business Process ImprovementBusiness Process Improvement
Business Process ImprovementAnand Subramaniam
 
Cio Council Erp Update 081309
Cio Council Erp Update 081309Cio Council Erp Update 081309
Cio Council Erp Update 081309James Sutter
 
Sourcing Governance and Leadership
Sourcing Governance and LeadershipSourcing Governance and Leadership
Sourcing Governance and LeadershipFrank Willems
 

Similar to Lean Transformation ~ A Journey (20)

Developing A Continuous Improvement Environment August 2009
Developing A Continuous Improvement Environment   August 2009Developing A Continuous Improvement Environment   August 2009
Developing A Continuous Improvement Environment August 2009
 
Lean Fundamentals And Line Design 06 04 01
Lean  Fundamentals And  Line  Design 06 04 01Lean  Fundamentals And  Line  Design 06 04 01
Lean Fundamentals And Line Design 06 04 01
 
RDrew Six Sigma Overview
RDrew Six Sigma OverviewRDrew Six Sigma Overview
RDrew Six Sigma Overview
 
00 Vital Links Lean Six Sigma Change Acceleration 38 Pgs
00 Vital Links Lean Six Sigma Change Acceleration 38 Pgs00 Vital Links Lean Six Sigma Change Acceleration 38 Pgs
00 Vital Links Lean Six Sigma Change Acceleration 38 Pgs
 
Implementing Balance Scorecard
Implementing Balance ScorecardImplementing Balance Scorecard
Implementing Balance Scorecard
 
Estimating your Process Projects presented at FSOkx BPM Forum
Estimating your Process Projects presented at FSOkx BPM ForumEstimating your Process Projects presented at FSOkx BPM Forum
Estimating your Process Projects presented at FSOkx BPM Forum
 
The AIT Group Story
The AIT Group StoryThe AIT Group Story
The AIT Group Story
 
Dennis Stevens - Using Agile and Lean to Lead Business Transformation
Dennis Stevens - Using Agile and Lean to Lead Business TransformationDennis Stevens - Using Agile and Lean to Lead Business Transformation
Dennis Stevens - Using Agile and Lean to Lead Business Transformation
 
Lss pharma presentation2-2006
Lss pharma presentation2-2006Lss pharma presentation2-2006
Lss pharma presentation2-2006
 
Suaju Company Presentation
Suaju Company PresentationSuaju Company Presentation
Suaju Company Presentation
 
Business Agility And Software Development Alan Chedalawada
Business Agility And Software Development   Alan ChedalawadaBusiness Agility And Software Development   Alan Chedalawada
Business Agility And Software Development Alan Chedalawada
 
Dimensions Of Change
Dimensions Of ChangeDimensions Of Change
Dimensions Of Change
 
How To Achieve Process Transformation In Any Organization PowerPoint Presenta...
How To Achieve Process Transformation In Any Organization PowerPoint Presenta...How To Achieve Process Transformation In Any Organization PowerPoint Presenta...
How To Achieve Process Transformation In Any Organization PowerPoint Presenta...
 
Role of the cio in the digital age
Role of the cio in the digital age Role of the cio in the digital age
Role of the cio in the digital age
 
Awareness To Lean & 7 Qc Tools
Awareness To Lean & 7 Qc ToolsAwareness To Lean & 7 Qc Tools
Awareness To Lean & 7 Qc Tools
 
Competing On Resources Balance Scorecard
Competing On Resources  Balance ScorecardCompeting On Resources  Balance Scorecard
Competing On Resources Balance Scorecard
 
Business Process Improvement
Business Process ImprovementBusiness Process Improvement
Business Process Improvement
 
Benchmarking
BenchmarkingBenchmarking
Benchmarking
 
Cio Council Erp Update 081309
Cio Council Erp Update 081309Cio Council Erp Update 081309
Cio Council Erp Update 081309
 
Sourcing Governance and Leadership
Sourcing Governance and LeadershipSourcing Governance and Leadership
Sourcing Governance and Leadership
 

More from Anand Subramaniam

More from Anand Subramaniam (20)

Anand dossier 2
Anand dossier 2Anand dossier 2
Anand dossier 2
 
Anand short dossier
Anand short dossierAnand short dossier
Anand short dossier
 
Set up reduction
Set up reductionSet up reduction
Set up reduction
 
Waste Walk ~ Audit
Waste Walk ~ AuditWaste Walk ~ Audit
Waste Walk ~ Audit
 
Muda in service industries
Muda in service industriesMuda in service industries
Muda in service industries
 
3 MU
3 MU3 MU
3 MU
 
Ninbennoaru Jidoka
Ninbennoaru JidokaNinbennoaru Jidoka
Ninbennoaru Jidoka
 
Gemba kaizen
Gemba kaizenGemba kaizen
Gemba kaizen
 
LSS Idea Generation to Project Execution
LSS Idea Generation to Project ExecutionLSS Idea Generation to Project Execution
LSS Idea Generation to Project Execution
 
LSS - 5 Year Strategy
LSS -  5 Year StrategyLSS -  5 Year Strategy
LSS - 5 Year Strategy
 
Lean Six Sigma Projects & Strategy Linkage
Lean Six Sigma Projects & Strategy LinkageLean Six Sigma Projects & Strategy Linkage
Lean Six Sigma Projects & Strategy Linkage
 
CMMI Capability Maturity Model Integration
CMMI   Capability Maturity Model Integration CMMI   Capability Maturity Model Integration
CMMI Capability Maturity Model Integration
 
8 D – Problem Solving Process
8 D – Problem Solving Process8 D – Problem Solving Process
8 D – Problem Solving Process
 
Total Productive Maintenance
Total Productive MaintenanceTotal Productive Maintenance
Total Productive Maintenance
 
TPM Implementation Strategy
TPM Implementation StrategyTPM Implementation Strategy
TPM Implementation Strategy
 
Overall Equipment Effectiveness
Overall Equipment EffectivenessOverall Equipment Effectiveness
Overall Equipment Effectiveness
 
Autonomous Maintenance
Autonomous MaintenanceAutonomous Maintenance
Autonomous Maintenance
 
VSM – Current & Future
VSM – Current & FutureVSM – Current & Future
VSM – Current & Future
 
Material Handling
Material Handling Material Handling
Material Handling
 
Service / Product Innovation
Service / Product InnovationService / Product Innovation
Service / Product Innovation
 

Recently uploaded

obat aborsi bandung wa 081336238223 jual obat aborsi cytotec asli di bandung9...
obat aborsi bandung wa 081336238223 jual obat aborsi cytotec asli di bandung9...obat aborsi bandung wa 081336238223 jual obat aborsi cytotec asli di bandung9...
obat aborsi bandung wa 081336238223 jual obat aborsi cytotec asli di bandung9...yulianti213969
 
PALWAL CALL GIRL ❤ 8272964427❤ CALL GIRLS IN PALWAL ESCORTS
PALWAL CALL GIRL ❤ 8272964427❤ CALL GIRLS IN PALWAL ESCORTSPALWAL CALL GIRL ❤ 8272964427❤ CALL GIRLS IN PALWAL ESCORTS
PALWAL CALL GIRL ❤ 8272964427❤ CALL GIRLS IN PALWAL ESCORTSkajalroy875762
 
GURGAON CALL GIRL ❤ 8272964427❤ CALL GIRLS IN GURGAON ESCORTS SERVICE PROVIDE
GURGAON CALL GIRL ❤ 8272964427❤ CALL GIRLS IN GURGAON  ESCORTS SERVICE PROVIDEGURGAON CALL GIRL ❤ 8272964427❤ CALL GIRLS IN GURGAON  ESCORTS SERVICE PROVIDE
GURGAON CALL GIRL ❤ 8272964427❤ CALL GIRLS IN GURGAON ESCORTS SERVICE PROVIDEkajalroy875762
 
PALWAL CALL GIRL ❤ 82729*64427❤ CALL GIRLS IN PALWAL ESCORTS
PALWAL CALL GIRL ❤ 82729*64427❤ CALL GIRLS IN PALWAL ESCORTSPALWAL CALL GIRL ❤ 82729*64427❤ CALL GIRLS IN PALWAL ESCORTS
PALWAL CALL GIRL ❤ 82729*64427❤ CALL GIRLS IN PALWAL ESCORTSkajalroy875762
 
Progress Report - UKG Analyst Summit 2024 - A lot to do - Good Progress1-1.pdf
Progress Report - UKG Analyst Summit 2024 - A lot to do - Good Progress1-1.pdfProgress Report - UKG Analyst Summit 2024 - A lot to do - Good Progress1-1.pdf
Progress Report - UKG Analyst Summit 2024 - A lot to do - Good Progress1-1.pdfHolger Mueller
 
2024 May - Clearbit Integration with Hubspot - Greenville HUG.pptx
2024 May - Clearbit Integration with Hubspot  - Greenville HUG.pptx2024 May - Clearbit Integration with Hubspot  - Greenville HUG.pptx
2024 May - Clearbit Integration with Hubspot - Greenville HUG.pptxBoundify
 
JEYPORE CALL GIRL ❤ 8272964427❤ CALL GIRLS IN JEYPORE ESCORTS SERVICE PROVIDE
JEYPORE CALL GIRL ❤ 8272964427❤ CALL GIRLS IN JEYPORE ESCORTS SERVICE PROVIDEJEYPORE CALL GIRL ❤ 8272964427❤ CALL GIRLS IN JEYPORE ESCORTS SERVICE PROVIDE
JEYPORE CALL GIRL ❤ 8272964427❤ CALL GIRLS IN JEYPORE ESCORTS SERVICE PROVIDEkajalroy875762
 
Getting Real with AI - Columbus DAW - May 2024 - Nick Woo from AlignAI
Getting Real with AI - Columbus DAW - May 2024 - Nick Woo from AlignAIGetting Real with AI - Columbus DAW - May 2024 - Nick Woo from AlignAI
Getting Real with AI - Columbus DAW - May 2024 - Nick Woo from AlignAITim Wilson
 
UJJAIN CALL GIRL ❤ 8272964427❤ CALL GIRLS IN UJJAIN ESCORTS SERVICE PROVIDE
UJJAIN CALL GIRL ❤ 8272964427❤ CALL GIRLS IN UJJAIN ESCORTS SERVICE PROVIDEUJJAIN CALL GIRL ❤ 8272964427❤ CALL GIRLS IN UJJAIN ESCORTS SERVICE PROVIDE
UJJAIN CALL GIRL ❤ 8272964427❤ CALL GIRLS IN UJJAIN ESCORTS SERVICE PROVIDEkajalroy875762
 
Beyond Numbers A Holistic Approach to Forensic Accounting
Beyond Numbers A Holistic Approach to Forensic AccountingBeyond Numbers A Holistic Approach to Forensic Accounting
Beyond Numbers A Holistic Approach to Forensic AccountingYourLegal Accounting
 
Abortion pills in Jeddah ! +27737758557, cytotec pill riyadh. Saudi Arabia" A...
Abortion pills in Jeddah ! +27737758557, cytotec pill riyadh. Saudi Arabia" A...Abortion pills in Jeddah ! +27737758557, cytotec pill riyadh. Saudi Arabia" A...
Abortion pills in Jeddah ! +27737758557, cytotec pill riyadh. Saudi Arabia" A...bleessingsbender
 
Pitch Deck Teardown: Goodcarbon's $5.5m Seed deck
Pitch Deck Teardown: Goodcarbon's $5.5m Seed deckPitch Deck Teardown: Goodcarbon's $5.5m Seed deck
Pitch Deck Teardown: Goodcarbon's $5.5m Seed deckHajeJanKamps
 
Jual obat aborsi Hongkong ( 085657271886 ) Cytote pil telat bulan penggugur k...
Jual obat aborsi Hongkong ( 085657271886 ) Cytote pil telat bulan penggugur k...Jual obat aborsi Hongkong ( 085657271886 ) Cytote pil telat bulan penggugur k...
Jual obat aborsi Hongkong ( 085657271886 ) Cytote pil telat bulan penggugur k...Klinik kandungan
 
10 Influential Leaders Defining the Future of Digital Banking in 2024.pdf
10 Influential Leaders Defining the Future of Digital Banking in 2024.pdf10 Influential Leaders Defining the Future of Digital Banking in 2024.pdf
10 Influential Leaders Defining the Future of Digital Banking in 2024.pdfciolook1
 
Ital Liptz - all about Itai Liptz. news.
Ital Liptz - all about Itai Liptz. news.Ital Liptz - all about Itai Liptz. news.
Ital Liptz - all about Itai Liptz. news.htj82vpw
 
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdfThe Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdfbelieveminhh
 
Moradia Isolada com Logradouro; Detached house with patio in Penacova
Moradia Isolada com Logradouro; Detached house with patio in PenacovaMoradia Isolada com Logradouro; Detached house with patio in Penacova
Moradia Isolada com Logradouro; Detached house with patio in Penacovaimostorept
 
Lundin Gold - Q1 2024 Conference Call Presentation (Revised)
Lundin Gold - Q1 2024 Conference Call Presentation (Revised)Lundin Gold - Q1 2024 Conference Call Presentation (Revised)
Lundin Gold - Q1 2024 Conference Call Presentation (Revised)Adnet Communications
 

Recently uploaded (20)

obat aborsi bandung wa 081336238223 jual obat aborsi cytotec asli di bandung9...
obat aborsi bandung wa 081336238223 jual obat aborsi cytotec asli di bandung9...obat aborsi bandung wa 081336238223 jual obat aborsi cytotec asli di bandung9...
obat aborsi bandung wa 081336238223 jual obat aborsi cytotec asli di bandung9...
 
Obat Aborsi Malang 0851\7696\3835 Jual Obat Cytotec Di Malang
Obat Aborsi Malang 0851\7696\3835 Jual Obat Cytotec Di MalangObat Aborsi Malang 0851\7696\3835 Jual Obat Cytotec Di Malang
Obat Aborsi Malang 0851\7696\3835 Jual Obat Cytotec Di Malang
 
PALWAL CALL GIRL ❤ 8272964427❤ CALL GIRLS IN PALWAL ESCORTS
PALWAL CALL GIRL ❤ 8272964427❤ CALL GIRLS IN PALWAL ESCORTSPALWAL CALL GIRL ❤ 8272964427❤ CALL GIRLS IN PALWAL ESCORTS
PALWAL CALL GIRL ❤ 8272964427❤ CALL GIRLS IN PALWAL ESCORTS
 
GURGAON CALL GIRL ❤ 8272964427❤ CALL GIRLS IN GURGAON ESCORTS SERVICE PROVIDE
GURGAON CALL GIRL ❤ 8272964427❤ CALL GIRLS IN GURGAON  ESCORTS SERVICE PROVIDEGURGAON CALL GIRL ❤ 8272964427❤ CALL GIRLS IN GURGAON  ESCORTS SERVICE PROVIDE
GURGAON CALL GIRL ❤ 8272964427❤ CALL GIRLS IN GURGAON ESCORTS SERVICE PROVIDE
 
PALWAL CALL GIRL ❤ 82729*64427❤ CALL GIRLS IN PALWAL ESCORTS
PALWAL CALL GIRL ❤ 82729*64427❤ CALL GIRLS IN PALWAL ESCORTSPALWAL CALL GIRL ❤ 82729*64427❤ CALL GIRLS IN PALWAL ESCORTS
PALWAL CALL GIRL ❤ 82729*64427❤ CALL GIRLS IN PALWAL ESCORTS
 
Progress Report - UKG Analyst Summit 2024 - A lot to do - Good Progress1-1.pdf
Progress Report - UKG Analyst Summit 2024 - A lot to do - Good Progress1-1.pdfProgress Report - UKG Analyst Summit 2024 - A lot to do - Good Progress1-1.pdf
Progress Report - UKG Analyst Summit 2024 - A lot to do - Good Progress1-1.pdf
 
2024 May - Clearbit Integration with Hubspot - Greenville HUG.pptx
2024 May - Clearbit Integration with Hubspot  - Greenville HUG.pptx2024 May - Clearbit Integration with Hubspot  - Greenville HUG.pptx
2024 May - Clearbit Integration with Hubspot - Greenville HUG.pptx
 
JEYPORE CALL GIRL ❤ 8272964427❤ CALL GIRLS IN JEYPORE ESCORTS SERVICE PROVIDE
JEYPORE CALL GIRL ❤ 8272964427❤ CALL GIRLS IN JEYPORE ESCORTS SERVICE PROVIDEJEYPORE CALL GIRL ❤ 8272964427❤ CALL GIRLS IN JEYPORE ESCORTS SERVICE PROVIDE
JEYPORE CALL GIRL ❤ 8272964427❤ CALL GIRLS IN JEYPORE ESCORTS SERVICE PROVIDE
 
Getting Real with AI - Columbus DAW - May 2024 - Nick Woo from AlignAI
Getting Real with AI - Columbus DAW - May 2024 - Nick Woo from AlignAIGetting Real with AI - Columbus DAW - May 2024 - Nick Woo from AlignAI
Getting Real with AI - Columbus DAW - May 2024 - Nick Woo from AlignAI
 
UJJAIN CALL GIRL ❤ 8272964427❤ CALL GIRLS IN UJJAIN ESCORTS SERVICE PROVIDE
UJJAIN CALL GIRL ❤ 8272964427❤ CALL GIRLS IN UJJAIN ESCORTS SERVICE PROVIDEUJJAIN CALL GIRL ❤ 8272964427❤ CALL GIRLS IN UJJAIN ESCORTS SERVICE PROVIDE
UJJAIN CALL GIRL ❤ 8272964427❤ CALL GIRLS IN UJJAIN ESCORTS SERVICE PROVIDE
 
Beyond Numbers A Holistic Approach to Forensic Accounting
Beyond Numbers A Holistic Approach to Forensic AccountingBeyond Numbers A Holistic Approach to Forensic Accounting
Beyond Numbers A Holistic Approach to Forensic Accounting
 
Abortion pills in Jeddah ! +27737758557, cytotec pill riyadh. Saudi Arabia" A...
Abortion pills in Jeddah ! +27737758557, cytotec pill riyadh. Saudi Arabia" A...Abortion pills in Jeddah ! +27737758557, cytotec pill riyadh. Saudi Arabia" A...
Abortion pills in Jeddah ! +27737758557, cytotec pill riyadh. Saudi Arabia" A...
 
Pitch Deck Teardown: Goodcarbon's $5.5m Seed deck
Pitch Deck Teardown: Goodcarbon's $5.5m Seed deckPitch Deck Teardown: Goodcarbon's $5.5m Seed deck
Pitch Deck Teardown: Goodcarbon's $5.5m Seed deck
 
HomeRoots Pitch Deck | Investor Insights | April 2024
HomeRoots Pitch Deck | Investor Insights | April 2024HomeRoots Pitch Deck | Investor Insights | April 2024
HomeRoots Pitch Deck | Investor Insights | April 2024
 
Jual obat aborsi Hongkong ( 085657271886 ) Cytote pil telat bulan penggugur k...
Jual obat aborsi Hongkong ( 085657271886 ) Cytote pil telat bulan penggugur k...Jual obat aborsi Hongkong ( 085657271886 ) Cytote pil telat bulan penggugur k...
Jual obat aborsi Hongkong ( 085657271886 ) Cytote pil telat bulan penggugur k...
 
10 Influential Leaders Defining the Future of Digital Banking in 2024.pdf
10 Influential Leaders Defining the Future of Digital Banking in 2024.pdf10 Influential Leaders Defining the Future of Digital Banking in 2024.pdf
10 Influential Leaders Defining the Future of Digital Banking in 2024.pdf
 
Ital Liptz - all about Itai Liptz. news.
Ital Liptz - all about Itai Liptz. news.Ital Liptz - all about Itai Liptz. news.
Ital Liptz - all about Itai Liptz. news.
 
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdfThe Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
The Vietnam Believer Newsletter_May 13th, 2024_ENVol. 007.pdf
 
Moradia Isolada com Logradouro; Detached house with patio in Penacova
Moradia Isolada com Logradouro; Detached house with patio in PenacovaMoradia Isolada com Logradouro; Detached house with patio in Penacova
Moradia Isolada com Logradouro; Detached house with patio in Penacova
 
Lundin Gold - Q1 2024 Conference Call Presentation (Revised)
Lundin Gold - Q1 2024 Conference Call Presentation (Revised)Lundin Gold - Q1 2024 Conference Call Presentation (Revised)
Lundin Gold - Q1 2024 Conference Call Presentation (Revised)
 

Lean Transformation ~ A Journey

  • 1. Lean Transformation A Journey Anand Subramaniam
  • 2.
  • 3.
  • 4.
  • 5.
  • 6.
  • 7.
  • 8. Internal Challenges Gap between enterprise resource planning (ERP) and factory floor Incompatible and Inconsistent systems Lack of timely information to make informed decisions Lack of strategy to unify information across manufacturing Lack of funds and/or lack of perceived value
  • 9. Best in Class – Strategic Actions Improve processes that manage the flow of material and information Lean Initiative Optimise performance at Individual plants and factories Drive standards and consistency Across Global manufacturing networks Improve Sales and Operations Planning Processes
  • 10. Improvements from Lean Implementation Adapted from: National Productivity Review, Industry Week, Deltapoint Actuals Total Cycle Time Revenues Inventories Invisible Inventories Blue-Collar Productivity White-Collar Productivity Availability Scrap Delivery Lead Times Time-to-Market Return-on-Assets 20 40 60 80 100 Ranges in % Improvement Best Practices from Actual Cases
  • 11. Lean Transformation – Implementation Implementation What are the key lean principles and practices? How do I transform my enterprise to lean? How do I assess my progress? Process / Checklist Enterprise Level Roadmap Enterprise Transition to Lean Lean Enterprise Self Assessment Tool
  • 12. Lean Transformation - Enterprise Approach Information Technology Certified Suppliers Uncertified Suppliers Warehouse Sales & Marketing Warehouse Customers Customer Service Accounting Engineering Human Resources Factory
  • 13. Enterprise Level Roadmap – High Level Entry / Re-entry Cycle Adopt Lean Paradigm Decision to pursue Enterprise Transformation Enterprise Strategic Planning Long Term Cycle Focus on the Value Stream Develop Lean Structure & Behavior Create & Refine Transformation Plan Focus on Continuous Improvement Implement Lean Initiatives Initial Lean Vision Lean Vision Lean Transformation Framework Short Term Cycle Detailed Corrective Action Indicators Outcomes on Enterprise Metrics Environmental Corrective Action Indicators Enterprise Level Transformation Plan + Source: MIT – Lean Aerospace Initiative Lean Impact
  • 14. Enterprise Level Roadmap – Detailed Scan the environment Segment the market Define leadership requirements Create leadership structures Define policies, objectives, targets and budgets Communicate! Communicate! Communicate! Play catchball with deployment teams Play catchball with action teams Use reliable, scientific methods at all levels Discover/correct performance variances Perform corporate diagnosis with top Champions Assess/analyse performance Capture learning and make it replicable Re-vision your strategy -- again Renew your business – in real time Use advanced planning methods Celebrate Success! Mission Statement Values Statement Vision Statement P/O Matrices Focus Team Charter Kickoff Promotion P/O Matrices Deploy- ment Plans P/O Matrices Action Plans Plan Summary CEDAC P/O Matrix Phase II: Pilot Phase I: Plan Phase III: Deploy Phase IV: Integrate Phase V: Excel business renewal strategy re-vision vision deployment implementation/adherence strategy re-vision Create mission; establish values Envision the future Study Missions Market Studies Product/ Market Matrix Technology Roadmaps Corporate Diagnosis Develop- ment Plan Relation- Ship Map Organi- graph Target/ means Analysis Finalise policies and budgets Target/ Means Analysis Target/ Means Analysis CEDAC JIT TPM CE Newsletter Website Progress Tables Site Visits CEDAC 5 Minute Meetings Weekly Meetings Monthly Meetings Study Missions Creative Thinking Bottom up Planning Strategic Scenarios Game Theoretic Models analysis and reflection business renewal  2003 Productivity, Inc. adC IP0201wc
  • 15. Example - Enterprise Level Roadmap Source: Productivity Inc.
  • 16.
  • 17.
  • 18. Lean Enterprise – Self Assessment Source: MIT – Lean Aerospace Initiative Why Communicate “lean” enterprise-wide What A “lean” vision How Learn from successful “ lean” implementations Who The Enterprise Leader When First step Where Enterprise-wide Information Technology Certified Suppliers Uncertified Suppliers Warehouse Sales & Marketing Warehouse Customers Customer Service Accounting Engineering Human Resources Factory
  • 19.
  • 20.
  • 21. Example - “Change - Checklist”
  • 22.
  • 23.
  • 24. Example - Value Stream Map
  • 25. Lean Building Blocks Value Stream Mapping Continuous Improvement Performance Measurement Performance Management Quick Changeover Standardised Work Batch Reduction Teams Quality at Source 5S System Visual Plant Layout POUS Cellular/Flow Pull/Kanban TPM POUS – point of use storage Source: Techhelp
  • 26. Waste Elimination Source: John Willey & Sons - 2009 97% NVA 3% VA Most Process Improvement Teams Attack this . . . . . . Achieve this 97% NVA Typical Value Stream Ratio Value-Added (VA) to Non-Value-Added Activity (NVA) . .and Ignore this Source: C. Fiore; Lean Strategies for Product Development , ASQ, 2003
  • 27.
  • 28.
  • 29.