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A process is lean when it delivers products and services that the customer wants at an acceptable price to value ratio Lean this way This presentation is a run-through of what makes Lean Practice important for modern business
Essential Lean Practice Lean Principles Approach Making   change Formula for success ,[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]
What’s stopping your business being the best?
Lean formula Load Capacity Gap Value demand Failure demand Runner Repeater Stranger Work Waste Value adding Necessary non-value adding Non-value adding Positive Underload – not greater than 80% Negative Overload – Muri Actions and feedback loops ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],+ + +
Waste not - want a lot Human system Natural, unrecognised waste Push down, pop up Treat the whole, not the parts Not just tools and techniques Self discipline Practice and training Fat reduction Mistakes are opportunities Being green Fast Flexible Fit for purpose Adaptable in performance Lean is continuous learning Lean fitness Applying lean is not just driving out waste Value added Not inventory Not delays or poor communication Not waste Customer willing to pay for ...
Lean Principles
Journey to where Everything is Right Lean Principles ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Lean themes Customer Beginning and end Purpose Big Picture  and end game Simplicity Anything else is dangerous Waste Endemic – it’s everybody’s problem Process Design for horizontal movement Regularity No surprises in operations Flow Continuous movement from start to end Evenness Level activity – or sink in killer wave Pull Synchronise to the customer beat Prevent Prevention is better than rework Time Reduce cycle time to make and deliver Improve Use continuous improvement  relentlessly Partnership Apply win-win in all areas Gemba Facts from the frontline Investigate Question and listen in the stream Variation Reduce variation, anticipate change Overburden Protect from overloading Think small Process models from the smallest component Trust Platform for sharing and action Knowledge Build explicit and implicit understanding Humility No one has all the answers Visibility Make operations transparent and visible Postpone Retain flexibility as long as possible Network Opportunities for value added in the stream Participation Involve all stakeholders, share data
Lean Approach Options
Lean Enterprise House Right process gives right results Value from developing people Organisational learning Challenge, Gemba Process mapping, value stream mapping PDCA, FAIR Kaizen 7 wastes JIT Pareto Teamwork 5 whys 5S Systems thinking Policy Deployment Your way
Intuitive Lean Simple and effective approaches PDCA FAIR Plan Do Check Act Focus Align Integrate Respond A3 problem solving ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
Flow Question Framework Create Can we produce what the customer wants when it is needed? Can we deliver what the customer wants and prepare for the next according to real demand? Maintain Organise Measure Can we keep the flow going so that it does not stop? Can we maintain a predictable flow rate in order to achieve planned performance? Are we organised to support flow through the whole process chain? Can we deal with variation? Can we react quickly to resolve problems and recover? Do we measure to promote actions which support flow? Do we know what it needed at each point in the process chain to achieve the overall goal? Are we developing the right resources and skills? VISION REWARD CUSTOMER   NEEDS SATISFACTION DESIGN DELIVER
Lean Techniques Techniques can be sophisticated  7 wastes - TIMWOOD ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],5S ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Process analysis ,[object Object],[object Object],[object Object]
Those Japanese and other words Muda Waste: the one to concentrate on Muri and mura cause waste Where else does it come from? Human systems Muri Over-burden: near capacity resources do not work optimally Mura Unevenness: fast uninterrupted flow not possible with uneven demand – queues and lead time build up Could the root cause of everything but probably it’s circular Gemba See for yourself what is happening in the workplace Heijunka Level to schedule – the secret weapon SMED Single (digit) Minute Exchange of Die – true for service too Pokayoke Failsafing and mistake proofing Genchi Genbutsu Facts for correct decisions and consensus from the source Hansei Relentless reflection Kaizen Continuous improvement TRIZ Theory of Inventive Problem Solving Jidoka - Andon Automation with human intelligence with signalling to stop process
Making change
Methods and skills Levers in the social system ,[object Object],[object Object],[object Object],[object Object],[object Object],Programme and project management ,[object Object],[object Object],[object Object],[object Object],Business change ,[object Object],[object Object],[object Object],[object Object],[object Object]
Service dimensions Service characteristics ,[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],Lean for better service ,[object Object],[object Object],[object Object],[object Object],[object Object]
Where is Six Sigma in Lean Practice? Is it possible to have Lean without Six Sigma? ,[object Object],[object Object],Same infrastructure ,[object Object],[object Object],[object Object],[object Object],[object Object],Oversight ,[object Object],[object Object],[object Object],[object Object],Shared approach and techniques ,[object Object],[object Object],[object Object]
A good read The Lean Toolbox: The Essential Guide to Lean Transformation by John Bicheno and Matthias Holweg PICSIE Books 4 th  Edition 2009

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Lean practice an effort worthwhile

  • 1. A process is lean when it delivers products and services that the customer wants at an acceptable price to value ratio Lean this way This presentation is a run-through of what makes Lean Practice important for modern business
  • 2.
  • 3. What’s stopping your business being the best?
  • 4.
  • 5. Waste not - want a lot Human system Natural, unrecognised waste Push down, pop up Treat the whole, not the parts Not just tools and techniques Self discipline Practice and training Fat reduction Mistakes are opportunities Being green Fast Flexible Fit for purpose Adaptable in performance Lean is continuous learning Lean fitness Applying lean is not just driving out waste Value added Not inventory Not delays or poor communication Not waste Customer willing to pay for ...
  • 7.
  • 8. Lean themes Customer Beginning and end Purpose Big Picture and end game Simplicity Anything else is dangerous Waste Endemic – it’s everybody’s problem Process Design for horizontal movement Regularity No surprises in operations Flow Continuous movement from start to end Evenness Level activity – or sink in killer wave Pull Synchronise to the customer beat Prevent Prevention is better than rework Time Reduce cycle time to make and deliver Improve Use continuous improvement relentlessly Partnership Apply win-win in all areas Gemba Facts from the frontline Investigate Question and listen in the stream Variation Reduce variation, anticipate change Overburden Protect from overloading Think small Process models from the smallest component Trust Platform for sharing and action Knowledge Build explicit and implicit understanding Humility No one has all the answers Visibility Make operations transparent and visible Postpone Retain flexibility as long as possible Network Opportunities for value added in the stream Participation Involve all stakeholders, share data
  • 10. Lean Enterprise House Right process gives right results Value from developing people Organisational learning Challenge, Gemba Process mapping, value stream mapping PDCA, FAIR Kaizen 7 wastes JIT Pareto Teamwork 5 whys 5S Systems thinking Policy Deployment Your way
  • 11.
  • 12. Flow Question Framework Create Can we produce what the customer wants when it is needed? Can we deliver what the customer wants and prepare for the next according to real demand? Maintain Organise Measure Can we keep the flow going so that it does not stop? Can we maintain a predictable flow rate in order to achieve planned performance? Are we organised to support flow through the whole process chain? Can we deal with variation? Can we react quickly to resolve problems and recover? Do we measure to promote actions which support flow? Do we know what it needed at each point in the process chain to achieve the overall goal? Are we developing the right resources and skills? VISION REWARD CUSTOMER NEEDS SATISFACTION DESIGN DELIVER
  • 13.
  • 14. Those Japanese and other words Muda Waste: the one to concentrate on Muri and mura cause waste Where else does it come from? Human systems Muri Over-burden: near capacity resources do not work optimally Mura Unevenness: fast uninterrupted flow not possible with uneven demand – queues and lead time build up Could the root cause of everything but probably it’s circular Gemba See for yourself what is happening in the workplace Heijunka Level to schedule – the secret weapon SMED Single (digit) Minute Exchange of Die – true for service too Pokayoke Failsafing and mistake proofing Genchi Genbutsu Facts for correct decisions and consensus from the source Hansei Relentless reflection Kaizen Continuous improvement TRIZ Theory of Inventive Problem Solving Jidoka - Andon Automation with human intelligence with signalling to stop process
  • 16.
  • 17.
  • 18.
  • 19. A good read The Lean Toolbox: The Essential Guide to Lean Transformation by John Bicheno and Matthias Holweg PICSIE Books 4 th Edition 2009

Editor's Notes

  1. Runner – a product or service having sufficient volume and familiarity to justify dedicated resources and standard processes Repeater – a product or service at intermediate volume and regularity which is handled by reconfiguring existing resources and processes Stranger – a product or service which is required intermittently and at low volume but still profitable or necessary to satisfy customers which is disruptive to resources and processes
  2. Six Rights (Peter Hines): Right product, place, time, quantity, quality, cost Principle 4 is important to service management – in happens naturally or should in simultaneous production and consumption 99% of a product becomes waste within 6 weeks of sale
  3. 25 themes – and more? What classification – input, process, output, policy, etc
  4. A more rigorous approach
  5. WORMPIT (variant on Ohno) : Waiting, Over-production, Rework, Motion, Processing, Inventory, Transport Other wastes: making wrong product, untapped human potential, excessive information/communication, time, systems, natural resources, knowledge Six Sigma techniques should be used: Measles chart Fishbone Lead and takt time calculations Box and whisker Frequency plots Confidence intervals Correlation Regression and trends Failure mode and effect analysis (FMEA)
  6. Waste: anything other than the minimum amount of equipment, material, parts, space and human resource which are absolutely essential to add value to the product [or service]
  7. More Peter Senge: The easy way out usually leans back in Cause and effect are not closely related in time and space Small changes can produce big results - but the areas of highest leverage are often the least obvious You can have your cake and eat it – but not all at once Dividing an elephant in half does not produce two small elephants There is no blame