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How 2 Lean
Chapter 1: Overview
@Edward Kemmerling Lean System Results
Instead of describing
Lean in terms of Tools
and Actions, let’s
describe lean in terms of
Desired Results
@Edward Kemmerling Lean System Results
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
THE BESTValue $$$
@Edward Kemmerling Lean System Results
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
The Bottom Line:
More Revenue..…+$$$$$$
Lower Cost……………....….-$
Increase Profit….$$$$$
WHY???
@Edward Kemmerling Lean System Results
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
HOW: ToolsTPM
5-S
HOUR BY HOUR BOARDS
VISUAL CONTROLS
STANDARD WORK
JOB ROTATION
ANDON
POKE YOKE
QUICK CHANGEOVER
8D PROBLEM SOLVING
TEAM MEETINGS
HOUR BY HOUR AND VALUE STREAM BOARDS
KAN BAN
THE LIST GOES ON AND ON…@Edward Kemmerling Lean System Results
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
HOW? Tools Example
@Edward Kemmerling Lean System Results
PROBLEM SOLVING/CONTINUOUS IMPROVEMENT
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
But… Why in the heck
isn’t it working for us???
@Edward Kemmerling Lean System Results
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
HOW Do We Make the
Greatest Impact (90%)?
Improve Enablers:
•Leadership
•Behavior Change
•Engage Everyone
@Edward Kemmerling Lean System Results
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
WE DO!!!
DO WHAT I
SAY
Help me with my
process.
@Edward Kemmerling Lean System Results
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
LET’S PLAY “PICK A TOOL”
TOOL: STANDARD WORK
PHYSICAL CHANGE: DESIGN A FORM & FILL IT OUT
PROCESS CHANGE: STANDARD, BEST PROCESS FOR EACH JOB
JOB ROTATION
BEHAVIOR CHANGE: OPERATORS OWN THE PROCESS
LEADERS GIVE OPERATORS WHAT THEY NEED
REGULAR AUDITS
LEADERSHIP ENGAGEMENT & COACHING
DRIVE WASTE ELIMINATION / CI
@Edward Kemmerling Lean System Results
90%
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
HOW MUCH TIME DOES
YOUR PLANT SPEND ON
COACHING BEHAVIOR
CHANGE?
Time To Teach
Operators How To
Improve Metrics?
Time To Change &
Improve YOUR
Leadership Behavior?
Time To Develop Effective
Team Leaders?
@Edward Kemmerling Lean System Results
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
HOW TO DO IT
(Action Plan)
1. Conduct Leadership Team Meetings
a) Review this presentation with them
b) Create a common future vision
c) Help them understand the differences from what they do now
d) Engage them
i. Complete Self Assessment
ii. Complete “Pick a Tool”
iii. Create action plans
2. Increase & Track Leadership Time on the Floor
3. Conduct individual Behavior Coaching Sessions
a) Self Assessment
b) Action Plans
4. Engage Leadership in Process Audits
a) Regular reviews of progress
b) Hold people accountable
5. Always focus on a lean system to satisfy the Customer@Edward Kemmerling Lean System Results
This document is a partial preview. Full document download can be found on Flevy:
http://flevy.com/browse/document/how-2-lean-summary-3352
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How 2 Lean Summary

  • 1. How 2 Lean Chapter 1: Overview @Edward Kemmerling Lean System Results
  • 2. Instead of describing Lean in terms of Tools and Actions, let’s describe lean in terms of Desired Results @Edward Kemmerling Lean System Results This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 3. THE BESTValue $$$ @Edward Kemmerling Lean System Results This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 4. The Bottom Line: More Revenue..…+$$$$$$ Lower Cost……………....….-$ Increase Profit….$$$$$ WHY??? @Edward Kemmerling Lean System Results This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 5. HOW: ToolsTPM 5-S HOUR BY HOUR BOARDS VISUAL CONTROLS STANDARD WORK JOB ROTATION ANDON POKE YOKE QUICK CHANGEOVER 8D PROBLEM SOLVING TEAM MEETINGS HOUR BY HOUR AND VALUE STREAM BOARDS KAN BAN THE LIST GOES ON AND ON…@Edward Kemmerling Lean System Results This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 6. HOW? Tools Example @Edward Kemmerling Lean System Results PROBLEM SOLVING/CONTINUOUS IMPROVEMENT This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 7. But… Why in the heck isn’t it working for us??? @Edward Kemmerling Lean System Results This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 8. HOW Do We Make the Greatest Impact (90%)? Improve Enablers: •Leadership •Behavior Change •Engage Everyone @Edward Kemmerling Lean System Results This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 9. WE DO!!! DO WHAT I SAY Help me with my process. @Edward Kemmerling Lean System Results This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 10. LET’S PLAY “PICK A TOOL” TOOL: STANDARD WORK PHYSICAL CHANGE: DESIGN A FORM & FILL IT OUT PROCESS CHANGE: STANDARD, BEST PROCESS FOR EACH JOB JOB ROTATION BEHAVIOR CHANGE: OPERATORS OWN THE PROCESS LEADERS GIVE OPERATORS WHAT THEY NEED REGULAR AUDITS LEADERSHIP ENGAGEMENT & COACHING DRIVE WASTE ELIMINATION / CI @Edward Kemmerling Lean System Results 90% This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 11. HOW MUCH TIME DOES YOUR PLANT SPEND ON COACHING BEHAVIOR CHANGE? Time To Teach Operators How To Improve Metrics? Time To Change & Improve YOUR Leadership Behavior? Time To Develop Effective Team Leaders? @Edward Kemmerling Lean System Results This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
  • 12. HOW TO DO IT (Action Plan) 1. Conduct Leadership Team Meetings a) Review this presentation with them b) Create a common future vision c) Help them understand the differences from what they do now d) Engage them i. Complete Self Assessment ii. Complete “Pick a Tool” iii. Create action plans 2. Increase & Track Leadership Time on the Floor 3. Conduct individual Behavior Coaching Sessions a) Self Assessment b) Action Plans 4. Engage Leadership in Process Audits a) Regular reviews of progress b) Hold people accountable 5. Always focus on a lean system to satisfy the Customer@Edward Kemmerling Lean System Results This document is a partial preview. Full document download can be found on Flevy: http://flevy.com/browse/document/how-2-lean-summary-3352
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