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1. Lean Tools and Processes:
How to Use Them in Your Business
Dale B. Wilen, PMP
©2013 International Institute for Learning, Inc., All rights reserved.

2. Dale Wilen
Senior Consultant – IIL
Distinguished Faculty – City University School of Business
BSME – South Dakota School of Mines & Technology
MAEd – University of Phoenix
PMP
Certified LSS Master Black Belt

3. The Lean Evolution
Lean began in manufacturing
The values and principles of Lean are now recognized
In the “back offices” and across industries – from medical to retail
Leaders are “thinking Lean”
“Business as usual” is probably inefficient and wasteful
Let’s discuss how you can use these ideas in your business

4. How can you apply Lean to your business?
What do you want to accomplish?
Cycle time reduction – whether in manufacturing or in the back offices?
Eliminating waste – excess inventory, motion, transportation?
Remove non-value added steps in processes?
Error proof your activities, products, and services?
Define and use best practices?

5. Traditional Lean Tools
Value Stream Mapping
Gemba Walks
5S
Standard work
Poka Yoke / Error proofing
Kaizen events

6. Value Stream Mapping – Finding Opportunities
VSM is a visual tool, depicting the flow of material or information
VSM is used to understand the processes of your business
VSM can be a plan to get from a “current state” to a “future state”
VSM by itself does not fix anything! (That’s often misunderstood.)
VSM makes visible opportunities and problem areas
Once identified, the problem areas are addressed with other tools

7. Gemba/Genba Walks – Observe the Workplace
“Genba” is the place where value is created
A Gemba walk is going there, looking for waste and opportunity
Management or the workforce should conduct these activities
“Fresh eyes” is often a good tactic to employ
Whether in an office or a factory, you can observe
Work in progress, wasted motion, confusion/disorganization

8. 5S – Organizing the Workplace
5 Japanese words – Seiri; Seiton; Seiso; Seiketsu; Shitsuke
5 English words – Sort; Sweep; Simplify; Standardize; Sustain
5S reduces clutter and confusion
5S improves the working environment
5S is effective in every type of workplace

9. 5S in the Shop
Organized tools makes them easy to find when needed
Standard tool locations make it easy to see if a tool is missing
Hazards are removed when things are in their place
Benefits:
Increased safety
Time savings are realized when the right things are in the right places
Morale is improved in a clean workplace

10. 5S in the Office
How many office supplies do you have?
Can you always find things when you need them?
Do you have duplicated resources in the office?
Is your office organized such that you work
efficiently?
Let me tell you about an office that needed to be
“5S’d”…

11. Standard Work – Find the Best Practices
Simply put, standard work is using best practices
It is NOT asking your employees to become robots!
The employees (the users) determine the best practices
Standard work removes variation in methods, tooling, and
practices
Standard work can be applied in the shop or in the office
Let me tell you how NOT to do standardization…

12. Standard Work – Why Should You Do It?
Why should you observe standard operations?
It’s the best method; it’s the proven method; it’s the law!
Standard work locks in improvements
Many times improvements are lost by “backsliding”
Standard work helps to “Maintain the Gain”
Standard work consists of three elements:
Takt time; work sequence; and standard work in process

13. Poka Yoke – Make It Hard to Do It Wrong
“It is good to do things right the first time; it is even better to make
it impossible to do it wrong the first time.”
Errors cause defects – and drive costs up
Errors may be caught by inspection – but not always
When humans are involved, there will inevitably be errors
Errors can be prevented – or warnings can be given
Error proofing should be simple and cheap

14. Kaizen – Improve the Process
Kaizen simply means “good change”
Any improvement activity might be thought of as a Kaizen
In Lean, a Kaizen event is often in the form of a workshop
These workshops are usually nimble and fast paced
They are a great method to use in urgent situations

15. That was Just Touching the Surface…
Obviously, there is much more to discuss regarding these tools
These are just a few of the tools that can help “Lean” your business
Some of the tools and approaches you’ve known all along
They are common-sense approaches that are logical and easy to
use
Lean is a journey and a mindset, not just a class or seminar!

16. Questions?

17. Intelligence – Integrity – Innovation
We invite you to take a closer look at what we can accomplish together.
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