lean through custom software
TRANSCRIPT
LEAN THROUGHCUSTOM SOFTWARE AND
DATABASES
Sebastien BuzitAhead Consulting(562) 277 [email protected]
Custom Software, Databases, and Dynamic Web Pages
Types of waste
• Transport
• Inventory
• Motion
• Waiting
• Overproduction
• Over Processing
• Defects
LEAN PRINCIPLES
EXAMPLE:
Purchasing – Request For Quotation Process
Email RFQ to supplier
Answer questions
Receive bid by email (in
standard or non-standard format)
Supplier 1
Supplier 2
Supplier 3
Email RFQ to supplier
Answer questions
Receive bid by email
…
x n
um
be
r o
f su
pp
liers
Email RFQ to supplier
Answer questions
Receive bid by email
Consolidate and analyze
EXAMPLE:
Purchasing – Request For Quotation Process
One automatic email sent to all suppliers
Answer questions and make answers available to all
suppliers
Suppliers place bids in web
portal
Automatic analysis and comparison
Use a web based quoting tool to generate RFQ’s, collect bids, and analyze results
EXAMPLE:
Kanban
• Many benefits
• Eliminates waste
However:
• Manual handling of Kanban cards
• No automatic signals, alerts, and notifications
• Limited capability to track, analyze, and report performances
• No data recording for analysis of historical data (manufacturing time, inventory levels,…)
Electronic Kanban• Automatically create Kanban cards
• Automatically send user defined alerts and notifications
• Real time dashboard of performances, inventory, …
• Storage of historical data for performance analysis
Small Midsize Business Communications:Hidden costs – SIS International ResearchA knowledge worker spends 3.5 hours / week waiting for information from others.
$9,970 per knowledge worker / yr
EXAMPLE:
Engineering – Knowledge Management
Engineering issue / design challenge
You know somebody has faced that
problem before
YES: go talk to that person
Pull up design documents
NO
Look for historical documents
Re-invent the wheel
How many engineering challenges have already been faced by that business?
Where does a new engineer find information about design guidelines, historical quality issues, preferred designs?
Typical business
• Searchable database of design
templates and guidelines
• Store design quality issues
• Store test data
EXAMPLE:
Engineering – Knowledge Management
• Promote design consistency
• Avoid repeating mistakes
• Increase design speed
• Improve design quality
• Can be used for employee
training
Implement a Knowledge Management database
(CUSTOM) SOFTWARE AND DATABASES
• Automate frequent, repetitive tasks
• Remove human processing errors
• Improve data visibility and reporting (performance data, action status)
• Easy access to real time data to act faster
• Can be customized to your processes
• Automatic communications for smoother processes
• Reduces employee work to value added tasks
• Accelerate business data analysis
• Store historical data for later continuous improvement analyses
SHOULD BE PART OF YOUR LEAN TOOLBOX
Great tools
to reduce
many
types of
waste
During a Value Stream review, ask yourself “could a software/computer help us do that better or faster?”
Benefits
INDUSTRY DATA
“Automated data collection and Information Technology (IT) solutions can play a key role in resolving these obstacles, yet these choices did not figure prominently in participants planned responses.”
The Lean Six Sigma Benchmark Report - Aberdeen Group
INDUSTRY DATA
The Lean Six Sigma Benchmark Report - Aberdeen Group
• MRP cannot handle our needs
• Cost to develop and implement
• Our site has specific processes and corporate IT does not have software to help with our needs
• We don’t know what is doable and what is not
COMMON OBSTACLES
Other software can connect to the ERP or the data tables and provide the tools your need
Unless you use large software companies with expensive software, cost is usually low compared to benefits (high ROI)
Develop site specific tools that can connect to your ERP
Ask your software development partners for an audit
THANK YOU!
For more information:
aheadconsulting.com
Sebastien BuzitAhead Consulting(562) 277 [email protected]