77. WHAT WE WANTED…
Team oriented approach
Concurrent work
Quick problem solving
Aligned project objectives,
outputs, metrics, action plans, and
reporting
Effective policy deployment
Increased value-added time
through tightly focused
workshops and meetings
2007 Lean Focus: Lean
Product Development
TPSは既に導入していたが
ホワイトカラーに???
TMSというマネジメントシステムを知る
78
78. PD Pilots Oobeya… independently
WHAT WE GOT was not an increase in efficiency
Time (by month)
Milestones, major
tasks, events &
activities
Organizations,Work
Groups
大部屋(TMS2級レベル)に
挑戦する。
79
79. 8
PD Pilots Oobeya…
• with consultants
• Kick-off
• Restructured Main Board
• Simple, visual format
• Few program targets to
focus team effort
• Tiered implementation,
engaging the whole team
• Lessons Learned:
• 3 levels of visualization
• Human-side of TMS system
• Value of the journey approach
• Depth gained from experiential learning
Leader
and
sub-
leader
for each
product
or
process
team
経営トップ自ら参画!!
80
80. Team Self-Assessment of Oobeya Benefits at 6-Month Mark
• Better visibility& engagement
• Improved communication, visibility of plan, and visibility of workload
• Improved engagement of leaders with whole team
• Improved prioritization across the team
• Greater accountability
• Focused targets drove team activity, increased proactive behavior
• Oobeya emphasized metrics, provided better alignment with yearly goals, and increased
individual accountability to team effort
• Integration of cross-functional activities improved significantly
• Quicker problem-solving, by valuing issue identification and resolving issues at the
First LfL Implementation in BCA
Program Management: Barashi,
Targets, And Metrics
Integrated Long-term
Schedule, with Reflections
Near-Term
Look-Ahead
Risk Management:
Issue Board
Product Development Oobeya Boards, late 2007
Targets Metrics
Leader
and
sub-
Leader
Airplane-level &
Team-level
Barashi
長期から短期までの経営目標を
各層で共有し一丸となって行動!!
81
81. TMS Implementation in BCA
• The BCA journey included “rebranding” TMS to Lean for Leaders (LfL)
• Our 4-year LfL history began in Product Development, expanded to 737 Engineering,
then to Functional Excellence & Product Integrity (Core Engineering), and most
recently to the entire 737 Program
• Oobeya – a consistent starting point:
• Introduces disciplined, structured reporting and quick problem solving
• Clarifies targets to drive focus and enhance long-term planning
• Improves efficiency and increases collaboration
• Instills PDCA for knowledge work
• LfL tools have been applied to resolve bottlenecks within implementing organizations
• Internal competency developed with BCA
• Lean practitioners
• Organizational leaders
• One organization has achieved the self-sustaining level
• Introduction of LfL Studio ensures continued development
文化を変える方法として
カイゼン塾(LfL:Lean for Leadsers)を採用
82
82. Phased Implementation of LfL
4
Project-side
Human-side
6 4
Self
Sustaining
LfL Studio
New Working
Culture
• New roles
Higher Perspective
Visualization
• Oobeya
Kick
-off
4
LfL Tools
•Improve
processes
• Resolve
bottlenecks • Working habits
• Accountablity
- Target
Decomposition
- Metrics
• Visual board
Minimum
Time (mo.)
83
83. Alignment of Functions with Programs
Program-
specific
Targets
Functional
Organization
Single
Function
Targets specific to
executive’s own
function
Programs1 2 3 … X
Targets set by
the functional
organization
大きな経営的成果を出すために
クロスファンクショナルな組織運営!!
(横糸の活動)
84
84. • Forward looking actions
• Most important part of the form
• Improved planning for next year
Even with highly success- ful efforts,
what issues did you encounter?
• Speciffiic accomplliishments
• Resultts of tteam efffortt
Resp..
Person
Goal tthat tthe org. iis Speciiffiic ttarget Trying tto
achieve w// measures
Metriic
& Target (W hat do we need tto do nextt?)
Issue
(For alll goals, regardlless of
assessment… ffor
contiinuous iimprovement)
Resullts
(W hat have we accomplliished ++
so far ttoward the targett?)
Performance
Goal//Theme
(W hattare we ttrying tto
accomplliish?)
Even with highly success- • Forward looking actionsful efforts, what issues did • Most important part of the form
• Improved planning for next year
you encounter?
++
Group
& Name to
--
Next step
Date: < xx/xx/xx >
Core IC Group– < add your group name here >
MISSION:
# OF STAFF SIGNATURELast Year This Year
BUDGETLast Year This Year
Budget
VP/Exec Responsible
Person
Leadership Team
Oobeya
1Q09 2Q09
3Q09 4Q09 1Q10 2Q10 3Q10
Issue Board: Panel
•Project Background
•Project Objective
•Technical Spec
•Project Organization
Potential Real Finish
Design
Engineering
Production
Marketing
Potential Real Finish
per week Design
Engineering
Production
Marketing
Objective Expected Output Metrics
Targ
et
1 2 3- 1
Targ
et
1 2 3- 1
Decomposition Area
Issue Board
Con-current Schedule
Frames
Jan Feb Mar ---
Design Dec
Engineering
Production
Marketing
Service
Con-current Schedule
Jan Feb Mar --- DecFram
es
Action Board
Design
Engineering
Production
Marketing
Service
Projector
for Virtual
Design
Review or
meeting
Expected OutputExpected Output
Prototype
Executive
Board
2-issues
•Progress check,
only Green &
Red
•All related members,
Planning, Design,
Production and Sales
& Marketing
• Identify issues
for management
decisions
Target
Decomposition
Weight
Cost
Capital
Targ
et
1 2 3 - 1
Targ
et
1 2 3 - 12
Targ
et
1 2 3 - 1
oo dd
22
Targ
et
1 2 3 - 1
Good
Go
Flammability - Deliverables (ACE ref.; %of Total)
0%
50%
100%
byMonth
%ofTotalDe
liverables
OpenDeliverables Past
Target
0 0 0 0 20 9 10 0 0 277 0
Complete Deliverables Past Target 75 42 10 56 17 2 2 0
0
73 0
Open Deliverables On-time 0 0 0 0 0 25 115 104
37
26 5
Complete Deliverables On-time 88 4 0 32 12 20 19 6
0
110 0
2009-12 2010-01 2010-02 2010-03 2010-04 2010-05 2010-06 2010-07 2010-08 2010-09
2010-10
Green
Target
Early Metrics
Metrics
Refinement
EOY
Reflection
Process
Leaders
negotiate
alternate
scenario
Team Level
Oobeya
initiated
Mid-year
Reflection
added
An Organization’s Visualization Phase
2010
starts w/
good plan
Weight Targ et
Good
Good
Cost 1 2 3 - 12
Targ et
Capital 1 2 3 - 12
85
85. 15
TLSC
Flammability: Project XX
Legend
ITCM Supplier Design
Printed out or
Input real document
Work
process Work
content
Output
Issue
Counter measure
Have issues and countermeasures
TLSC
Flammability: Project XX
Legend
ITCM Supplier Design
Printed out or
Input real document
Work
process Work
content
Output
Issue
Counter measure
Have issues and countermeasuresHave issues and countermeasures
TLSC
dbackdback sshheeeett
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description 5
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description 5
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description 5
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description 5
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Y our task descrip tio n
--
g o es he r e
6
Y our task descrip tio n
--
g o es he r e
6
Y our ta sk desc r i pti on
--
g o es h er e
6
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--
g o es h er e
6
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6
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6
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description 5
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description 5
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6
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description 5
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description 5
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description 5
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description 5
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description --
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6
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description --
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6
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description --
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6
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description 5
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6
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description 5
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6
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description 5
goes here
Individual
Visibility
Susan
5/17-21
5/24-285/31–6/46/7-11
1Q09 2Q09 3Q09
Selecting the RIGHT Solution
4Q09 1Q10 2Q10 3Q10
Feedback Sheets for
Lessons Learned
Your taskdescription 5 description 5
goes here
Your task
goes here
Your task
description
goes here
5 Your task
5
description
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description 5
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160%
5 Your task
6
description --
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description
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5
6
Your task
description
goes here
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Workload
Visibility
Portable
Project
Boards
BBooddyy
EEnnggiinnee
SSyysttem,, Electtric
Ettcc..
Process & Process
European driving taste
CChhassiis,,
SSuussppeennssiioon-
Expected OOuu-ttpputt
Expected
performa
nce?
Sports Double
wishbone
Strut
Leaf
spring
Heavy duty
Shock reso n of
alt ernativ e
absorber
Rubber
Bush
Arm
- - -
Three linkCanceled
rigid axle -- X
Questi
on &
Spring Issue
R ecord
Canceled
- - - -- X
Off-road Air
setting
Oil
Electric
Specification
Spring– 111-333
Shock– 234-323
Arm– 786-388
Specification
Spring– 908-763
Shock– 234-323
Arm– 786-388
Specification.
Spring– 908-763
Shock– 234-323
Arm– 786-388
R ecord reson
of alternat iv e
Questi
on &
Issue
Test data
Decision or
Turing
points
Grouping or
Alternative
Legend
Record
reson of
alternative
Canceled
-- X
Same Organization:
Higher Perspective Phase
Improve the Process
TLSC
Flammabil
ity:
Projec
t XX
Legend
ITCM Supplier Design
Printed out or
Input real document
Work
process Work
content
Output
Counter
Solution
Selected
Solution
Question & Issue
86
86. Lessons Learned through the Journey
• Starting with the leadership team is crucial
• Visualization provides early benefits
• Culture change follows persistent effort
• An 18 – 24 month commitment is necessary
• Hard work is required
• Unwillingness to try a new method will
dampen culture change
• Tools and methods, once tried and practiced, can be
effectively tailored to the organization’s specific
needs
87
87. Board Format Explanation
Carolyn
• Barashi
• Target
TOP LEVEL
MIDDLE LEVEL
WORKING LEVEL
Long-term plan
Jan Feb ---
Carolyn
Level 1
Level 1
• Barashi
• Target
Long-term plan
Jan Feb ---
Level 1
Senior
Metrics
Metrics
Long-term plan
Jan Feb ---
1st Line A
Member
1st Line A
1st Line
• Barashi
• Target
• Specific for A
1st Line A
• Target
Long-term plan
Jan Feb ---
1st Line B
Member
1st Line B
1st Line
• Barashi
• Target
• Specific for B
1st Line B
• Target
Metrics
1st Line C
• Specific for C
• Senior needs to join as
possible as meeting
Long-term plan
Jan Feb ---
Senior
1st Line
Senior
Board Format Explanation
大きな経営的成果を出すために
縦糸の強化(バラツキの撲滅)
方針展開
88