August 25, 2016

1. Mark Graban
@MarkGraban
www.PracticingLean.com
www.LeanBlog.org
Slides & More:
www.MarkGraban.com/LALMS
Reflections on 20+ Years
Trying to Get Better at Lean
in Manufacturing & Healthcare

2. www.louisebatz.org

3. Practicing Medicine

4. Practicing Law

5. Practicing Lean?
© Nicole Yearly (“chicagozen“ on Flickr), used under Creative Commons License

6. Implementing

7. Practicing

9. Learning

10. Learning
By
Doing

11. Learning
By
Doing*
*With a Qualified Coach

12. “I’m Jim Pell.
I’ve been
learning Lean
for 25 years.”

13. Learning
Through
Mistakes

14. e
We All
MAke
Misteaks

16. One of
My
Mistakes
(2004)

17. “My” Kanban System
When inventory reaches 2160,
take care to Level 4
Meterbody kanban board.
Qty to build: 660 units
Actual Build Qty:

19. “My” Kanban System
When inventory reaches 2160,
take care to Level 4
Meterbody kanban board.
Qty to build: 660 units
Actual Build Qty:

20. Or…

21. ean
s
isguidedly
xecuted

22. Or…
Just not good
at this yet?

23. Their Kanban System

24. We All Start
Somewhere

25. ean
s
istakenly
xplained

26. “Toyota would tell you to
kick the patient out of the
room at 19:59 because you
have to keep on takt time.”

27. Dunning-Kruger Effect
Unskilled and unaware of it: how difficulties in
recognizing one’s own incompetence lead to inflated
self-assessments – Kruger & Dunning (1999)
100%
0%
None Experience Expert
Confidence

28. We All Start
Somewhere

29. “Which
Lean Tool
Should I
Start With?”

30. Start from need.

31. What problem are
we trying to solve?

32. “Which
Lean Tool
Should I
Start With?”

33. “Always start
with 5S”

34. “Always start
with 5S?”

35. We’ve
Always
Done it
That Way

36. Toyota
Production
System

37. Thinking
Production
System

38. Learn, But Don’t Copy

39. ean
s
isguidedly
xecuted

41. Right Tool, Wrong Culture
7 am
8 am
9 am
10 am
11 am
12 am
1 pm
2 pm
92
92
92
92
92
92
92
92
BLOCKS • Plan
• Actual
• Reasons why

42. Right Tool, Wrong Culture

43. Right Tool, Wrong Culture
7 am
8 am
9 am
10 am
11 am
12 am
1 pm
2 pm
92
92
92
92
92
92
92
92
BLOCKS
60
60
60
60
45
60
14
30

44. My GM Mistakes
• Ergonomic assist
• Kanban tooling board
• Calling out the manager
• Quality or cost?

46. 1996 Current State at GM
• Worst performing engine plant
• Worst performing part of GM Powertrain
• Worst performing part of GM N.A.
• Worst performing part of GM
• Worst performing automaker

55. "We were offering suggestions
and getting pushback on safe
staffing, yet being told to reduce
the number of pens and pencils.”

56. Or…

61. ean
s
istakenly
xplained

62. “Go ahead and use Lean on
that quality problem…
you’ll speed up your quality problem
and make bad stuff faster.”

65. “Lean will help you to reduce or
eliminate [wastes] 1 through 6.
Six Sigma will help you to
reduce number 7 [defects].”

66. Jidoka Just-in-Time

68. “If lots of
people are
upset, it’s not
really TPS.”

69. Complaining
About
Resistance

70. Complaining
About Lack of
Sustainment

71. “We were only holding
the gains on about
40 percent
of those
[Kaizen Events]”

72. Lack of
Adoption?

75. “We’ve been
implementing Lean
for 5 years…
now we’re focusing on
continuous improvement.”

77. Why
Lean?

79. Why
Lean?

82. 90%??

83. Why Be
Better at
Lean?

86. • Don’t be afraid to make mistakes
• Learn from the mistakes of others
• Try to anticipate possible mistakes
• Make small mistakes to prevent
big mistakes
• Don’t keep making the
same mistakes
If You’re New to Lean…

87. • Share your early mistakes
• Call out “Fake Lean?”
• Be patient & respectful
• Always be a learner, and be
making new mistakes
If You’re Experienced…

88. • Make sure you’re staying true to Lean
without being too dogmatic
• Think about how people might
misunderstand what you’re teaching
• Discuss pro-active countermeasures
to L.A.M.E. or “Fake Lean”
If You’re Teaching…

89. Learn by
doing
Do it right
the first time

92. Q&A / Contact Info
• www.MarkGraban.com
• www.LeanBlog.org
• mark@markgraban.com
• Slides & More:
www.MarkGraban.com/LALMS
www.PracticingLean.com