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Lean Thinking for Ukraine 2017 and Beyond. Lean Enterprise Institute. John Shook

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История развития Лин мышления и Lean Global Network. Основные парадигмы лежащие в основен Бережливого производства.

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Lean Thinking for Ukraine 2017 and Beyond. Lean Enterprise Institute. John Shook

  1. 1. Istituto Lean Management Lean Thinking for Ukraine 2017 and Beyond John Shook Lean Enterprise Institute – USA Lean Global Network – Earth (Planet Lean) LEAN GLOBAL NETWORK
  2. 2. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Australia — Lean Enterprise Australia Brasil — Lean Institute Brasil China — Lean Enterprise China Denmark — Confederation Danish Industries France — Project Lean Enterprise Hungary — Lean Enterprise Institute India — Lean Management Institute Israel — Israel Lean Enterprise Italy — Instituto Lean Management Mexico — Lean Enterprise Mexico Netherlands — Lean Management Instituut Poland — Lean Enterprise Institute South Africa — Lean Institute Africa Spain — Instituto Lean Management Turkey — Lean Institute Turkey U.K. — Lean Enterprise Academy Ukraine – Lean Institute Ukraine U.S.A. — Lean Enterprise Institute Making Things Better Through Lean Thinking and Practice LEAN GLOBAL NETWORK 2017
  3. 3. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Sparking a Movement LEAN GLOBAL NETWORK James P. Womack Daniel T. Jones
  4. 4. © Copyright 2015 Lean Enterprise Institute. All rights reserved. • Product and process development • Supplier management • Customer management • Production • General management 4 Interlocked Management Innovations
  5. 5. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Stability – Improvement – Innovation 5 1914 2014
  6. 6. © Copyright 2015 Lean Enterprise Institute. All rights reserved. From Automobiles to… § Global Auto Industry § Discrete Manufacturing § Process Industries § Healthcare § Services § Knowledge Work
  7. 7. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Lean Institute Ukraine – Key Members Serhii Komberianov President Ruslana Postupalenko Executive Director Peter Willats Advisor Yalcin Ipbuken Coach & Advisor Valeriia Zabolotna Advisor
  8. 8. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Well
  9. 9. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Learning to See § “Every product has a value stream. The challenge lies in seeing it.” § Rother and Shook
  10. 10. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Learning to See
  11. 11. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Learning to See
  12. 12. © Copyright 2015 Lean Enterprise Institute. All rights reserved. What To Do? Reduce Lead Time! • Get each process to produce only what the next process needs when it needs it. • Orchestrate (control, manage, regulate) operations to get ever closer to this ideal, ever shortening the lead time. ORDER CASH “All we’re trying to do is shorten the time line…” Taiichi Ohno
  13. 13. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Raw Material PROCESS VALUE STREAM Finished Product PROCESSPROCESS Stamping Welding Assembly Cell Actual processing steps can be hard to improve; the time between each step—stagnating time!—is a great opportunity for Ukrainian companies ORDER CASH
  14. 14. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Current State Map
  15. 15. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Takt Time = 58 <5d Future State Map
  16. 16. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Mapping all the way to the Customer
  17. 17. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Mapping the Future State to the Customer
  18. 18. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Efficiency and Service Levels
  19. 19. © Copyright 2015 Lean Enterprise Institute. All rights reserved.
  20. 20. © Copyright 2015 Lean Enterprise Institute. All rights reserved.© Copyright 2015 Lean Enterprise Institute. All rights reserved. Daily Management Routine 6:00 – 6:15 AM Operators Team Leaders React To Environmental Change 6:15 – 7:00 AM Team Leaders Factory Leaders React To Environmental Change 7:00 – 8:00 AM Factory Leaders Mfg Manager React To Environmental Change 9:40 – 9:50 AM Mfg Manager Senior Leadership Team React To Environmental Change
  21. 21. © Copyright 2015 Lean Enterprise Institute. All rights reserved. New United Motor Manufacturing, Inc. – NUMMI – kick-started a revolution that led to us meeting here today.
  22. 22. © Copyright 2015 Lean Enterprise Institute. All rights reserved. The Worst Factory in the World…
  23. 23. © Copyright 2015 Lean Enterprise Institute. All rights reserved. The Worst Factory in the World… Certified Worst!
  24. 24. © Copyright 2015 Lean Enterprise Institute. All rights reserved. 24 The Worst People…
  25. 25. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Certified! From the Worst to the Best… 25 GM Framingham Toyota NUMMI Assembly Hours per Car 31 16 19 Assembly Defects per car 135 45 45 Inventory 2 weeks 2 hours 2 days
  26. 26. © Copyright 2015 Lean Enterprise Institute. All rights reserved. What is the Role of Leadership?
  27. 27. © Copyright 2015 Lean Enterprise Institute. All rights reserved. 27 “Lead as if you had no power”
  28. 28. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Kan Higashi to Gary Convis… (NUMMI’s senior Japanese and American operational leaders) “Lead the organization as if you have no power.“ Build trust. Develop Problem solvers.
  29. 29. © Copyright 2015 Lean Enterprise Institute. All rights reserved. “Lead as if you had no power”
  30. 30. © Copyright 2015 Lean Enterprise Institute. All rights reserved.
  31. 31. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Lean Practice Across the Enterprise Product & Process Development Distribution, Fulfillment Operations, Production Sales & Marketing Support Functions – HR, Accounting, Finance, IT
  32. 32. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Learn and Share: Planet-lean.com 32 Monthly Column by Jim Womack
  33. 33. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Sciences of Value Creation Efficiency – Flow – Quality – Lean 1910 1922 1934 1946 1958 1970 1982 1994 2006 Today A lean future? Ukraine 2017 Machine That Changed the World 10/20/1990 IMVP Lean Production Start of Lean Diffusion, (and Dilution) 9/17/1988 NUMMI 12/12/1984 Early Explorers to Toyota City Toyota TPS/TMS Transfer of USA Quality and Productivity Technology to Japan Sept 1949 K Toyoda - JIT 1938 S Toyoda - Jidoka Taylor, Ford, Dewey, Fayol, Pareto, Gilbreaths, Shewhart Rise of Industrial Problem-Solving 1910 - 1950 Incubation 1950 - 1980 Diffusion 1984 - 2017 Future Direction 2017 john shook
  34. 34. © Copyright 2015 Lean Enterprise Institute. All rights reserved. Lean Production, Lean Thinking, Lean Enterprise, Lean Learning

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