achieve lean excellence lsg 0800

7/27/2019 Achieve Lean Excellence LSG 0800

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30 April, 2013

S A Partners

Achieve Lean Excellence

Learn-Share-Grow Webinar Series

Professor Peter Hines


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30 April, 2013

S A Partners

Welcome Webinar will last about 1 hour

We will invite you to completea few Polls

Q&A session

Our Webinar


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30 April, 2013

S A Partners

Professor Peter Hines

Co-founder Lean

Enterprise ResearchCentre, Cardiff University

Chairman, S A Partners Adjunct Professor,

University of SouthAustralia

Welcome!


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30 April, 2013

S A Partners

Muda, Mura and Muri

Mura

(unevenness)Muda

(waste)

Muri

(overburden)


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30 April, 2013

S A Partners

Lack of a clear executive vision Lack of an effective communication strategy Failure to create and communicate a real sense of urgency Poor consultation with stakeholders

Lack of structured methodology and project management Failure to monitor and evaluate the outcome Failure to mobilise change champions Failure to engage employees

Absence of a dedicated and fully resourced implementationteam Lack of sympathetic and supportive Human Resources

policies

Top 10 Reasons for Failure

Source: Lucey, Bateman & Hines, 2005


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30 April, 2013

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Kaizen Blitz vs. LeanManagement

I m p r o v e m e n t O p p o r t u n i t y

Time

Short termgains made

Lost and repeated resultsdue to no sustainability

Results could be lost entirelyif organizational structure notaligned to support and educationlevel of all employees not increased.

Improvement leveled off andeventually stopped due to lackof realizing true leanopportunity

Greater, sustainedresults achieved

Awareness, education,organisation structurecreated to support lean Source: C. Craycraft, Whirlpool

Utilization of Lean tools will deliver

performance improvement. However,behaviors focused on Continuous

Improvement / Pursuit of Perfection willprovide sustainable long term

improvement


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Is your lean programme closer to the kaizen blitzapproach or true lean approach?

Please select one or the other

Poll



Sustainable Lean Management

Lean Management

Source: P. Hines, P. Found, G. Griffiths & R. Harrison, Staying Lean, 2008



Cogent Power Case



An urgent need for change

Substantial Pre-tax losses in 2003 from Global operations Business was losing cash from a number of its Operating

Plants Seven Global Operating units Relatively Static order book with emphasis towards lower

margin products New CEO put in place to Lead the business TURNAROUND

strategy Experienced Senior Management Lean Team appointed to

support



Internal Value Stream focus

Hines, Found, Griffiths & Harrison, 2008



The roadmap to sustainability

4

3

1

2

Roadmap 1

Launched Jan 2004



Roadmap 1: StrategyFormation & Deployment

Leadership structure confirmed and aligned to the turnaround Kicked-off with top level awareness & Strategy sessions International & regional management teams CSFs & KPIs Lean message communicated from the top to help

deployment



Roadmap 1: People Skills andValue Stream Mgt

Selection process to ensure that the right coaches chosen Extensive Lean coach programme theory & practical Lean coaches developed hands-on experience in tools Steering team meeting and best practice sharing events



Roadmap 1: Internal VSM andLean Toolkit

Visual Impact with 5S, TPM & SMED at all sites High levels of engagement with site cross-functional teams Process stability being used to help introduced pull systems Gold Star standards using 6 Sigma set for heavy industry



Roadmap 1: Basic Customer Value& Office Lean

Customer Value assessments for all businesses Sales acquisition mapping used to improve order creation process Office 5S used to improve sales requisition process time Lean tools and deployment evident in many support areas



Maturity AssessmentBusiness to business benchmark

Stage 1Reactive

1. Reactive Approach2. 2. Little / No

Involvement3. Adhoc Learning

Stage 4Autonomous

Stage 5Way of Life

Stage 2Formal

Stage 3Deployed

1. Formal Structure2. Only Specialists3. Team Learning

1. Goal Oriented2. Selected Team3. Value Stream

Learning

1. Autonomoushabit

2. FullEmpowerment

3. External Learning 1. Driven Deployment2. Majority

Involvement3. X-process Learning

Key Characteristics

1. Ways of Working 2. Employee Engagement3. Learning Best Practice



A Sustainable Journey

R

ve

F

ma

D

oe

A

o

mo

W

o

fe

Mo

sao

B e n e f i t

Time



Which stage of this journey do you think you are?

Please select one answer

Poll



Organisational LearningLean Maturity Assessment



Organisational LearningLean Maturity Assessment

The coaches have become the leaders of Lean Real Lean management is still an exception LEAN is too cosmetic and not fully impacting profit LEAN still seen as an initiative and not given

priority OEE and Pareto are hardly used to drive

improvement

Lean is not driving changes in managementbehaviour Responsibility and accountability not fully deployed



Maturity Assessment: Under theWaterline

Unstable IcebergModel

Technology, tools andtechniques

ABOVE WATERLINE - VISIBLE ABOVE WATERLINE - VISIBLE

Supply chainintegration

Processmanagement

UNDERWATER - ENABLING UNDERWATER - ENABLING

Behaviour and engagement

Strategy and alignment

Leadership

Enabling Features Not Fully Addressed

NARROWING UNDER WATERLINENARROWING UNDER WATERLINE



The Roadmap to Sustainability

Roadmap 2

Reviewed July 2005

3

2

1

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Roadmap 2: Multi-level Leadership& Deployment

Leadership developed at every level of the organisation (7Values)

Clearly defined roles & behaviours for self-managedteamworking

Re-deployed targets aligning OF / OC / NPI processes Full line of sight deployment locked into key processes


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Roadmap 2:Lean and the Extended Enterprise

Focus on sustained profitability in strategically selected areas Sustained operational performance metrics on key Value

Streams Aligning supplier and customer processes via CAMBAN

technology Operational capability now leading to sales growth opportunities


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Roadmap 2: Customer Value &Supplier Integration

Detailed Customer Value extending throughout the supply chain Adapting process to meet with Customer & business needs Product / process development exceeding Customer

expectations Extending the offering and bridging the supply-chain


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Lesson: Focus Under theWaterline

Focus below the waterline in order to deliver the sustainable businessresults required to keep you continuously above the waterline


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Lowering the Water Level


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Lowering the Water Level


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Which elements of the Lean Iceberg do you need topay more attention to?

Strategy & Alignment Leadership Behaviour & Engagement Tools & Techniques Processes

Multiple choice with multiple answers

Poll

S F f S i bl


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Success Factors for SustainableChange

L M t it d


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Lean Maturity andOrganisational Learning

Ad-hoc FormalGoal

orientedManaged

AutonomyWay of Life

A c h i e v e

m e n t

Knowing Organisation

Understanding Organisation

Single looplearning

Double looplearning

Step change in learning occurswhere the organisation can achieve

higher results than previously imagineddue to lack of knowledge of what waspossible

Bessant& Caffyn

McGill &Slocum

Senge

Push

Lean PullLean

Thinking Organisation

Learning Organisation


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What further activity would you like?

Please select one or more answers

Poll


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If you would like to discuss anything coming out of the webinar please contact me at:[email protected]

or +44 (0)7974 416660 Please also link up with me at

uk.linkedin.com/in/profpeterhines/

Further Questions
mailto:[email protected]://uk.linkedin.com/in/profpeterhines/http://uk.linkedin.com/in/profpeterhines/http://uk.linkedin.com/in/profpeterhines/http://uk.linkedin.com/in/profpeterhines/mailto:[email protected]


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Cardiff University accredited training in Melbourne,Sydney and Brisbane. See more details on:http://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdf

Lean and Green free webinar with Dr Keivan Zokaeion the 4 th June . See more details on:http://www.sapartners.com.au/thought-

leadership-in-the-area-of-lean-and-green-2/ Or Contact our Australian MD Chris Butterworth on

[email protected]

Australian Events
http://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/mailto:[email protected]:[email protected]://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdf


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Staying Lean Event 5th

July Birminghamhttp://www.sapartners.com/staying-lean-thriving-not-just-surviving/

Learn-Share-Grow Event June 24 th & 25 th at Genzyme Waterford,Irelandhttp://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/

The Book Launch of Creating a Lean & Green Business System,June 20 th at The Bridge House, Tower Bridge Road, Londonhttp://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/

European Events
http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/

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