lean training final deck
TRANSCRIPT
Lean TrainingModule Task Information
What is Lean?
• An evolutionary search for better processes that is never complete.
• A strategy for maximizing value for the customer.
• Straightforward principles tied to deceptively difficult execution.
• A set of principles that can apply to any process.
The relentless pursuit of the perfect process through waste elimination
Starting with basics…The word Lean has 3 Core Purposes
ü Create Value As defined by the Customer
ü Focus on ProcessA value-stream creating Process Flow that begins with “Pull” from the Customer.
ü Eliminate Non-Value Activity (Waste/Muda)
“Look at the time-line from the moment the customer gives us an order to the point when we collect the cash and reduce that time-line by removing non-value added wastes to create a LEAN process”
~Taiichi OhnoFounder, Toyota Production System
Why implement Lean?
• Improve performance• Increase capacity• Increase quality through simplification
• Increase customer/market responsiveness through cycle time reduction
Customer satisfaction = business prosperity
TYPES
OF
WASTE
Extra
Processing
Motion
Waiting
Defects
Over
ProductionTransport-
ation
Inventory
7 Types of WASTE: TOM-WIDE
Inventory
Defects
Over
Production
Motion
Transportation
Waiting
Identifying Waste (Muda)
“Lean” Targets the Waste and Eliminates It ... QUICKLY!
PEOPLE
QUANTITY
QU
ALIT
Y
Extra
Processing
Coffee Shop Example
Enter to Coffee Shop
Order Coffee Pay Receive your exchange ticket
Look for a table
Enjoy your coffee
Order Preparation
Coffee Shop Example
Enter Coffee Shop
Order Coffee Pay your Order
Receive your exchange ticket
Look for a table
Enjoy your coffee
Order Preparation
WAITING WAITING DEFECTS
WAITINGMOTION
DEFECTSMOTION
TRANSPORT-ATION
The 5 steps to Lean Thinking …
Specify valueValue is what the customer is
willing to Pay for!
Coffee Shop value = Beverage/food, place to
sit/work/socialize
2 Map the
Value Stream
3Establish
Flow
4Implement
Pull
5Work to
Perfection
1Specify Value
Introduction to Lean
The 5 steps to Lean Thinking …
Map the Value Stream
Map all of the steps…value added & non-value added…that bring a
product of service to the customer
2 Map the
Value Stream
3Establish
Flow
4Implement
Pull
5Work to
Perfection
1Specify Value
Introduction to Lean
Any Process has at least three versions
Why Map a Process?
What you THINK it is: What it ACTUALLY is: What it should be:
The 5 steps to Lean Thinking …
Establish Flow
The continuous movement of products, services and information
from end to end through the process
2 Map the
Value Stream
3Establish
Flow
4Implement
Pull
5Work to
Perfection
1Specify Value
Introduction to Lean
Flow is…• Movement of products, services and information down the
value stream
• Objective is continuous flow as product, service and information is transformed by continuously adding value
• Flow is created by eliminating Queues and Stops and improving process flexibility & reliability
Receive Order Write Down Order
III50
= 14 = 5
5 Days
Process Order
= 10
5 Minutes
Before After
After Takt Time – 1min
One single Piece Flow
“Real World” Flow at Drive Thru
1 Car Ordering
1 Car Paying
1 Car Picking Up Food
1 Car Exiting
BeforeInterminable queues inside and
outside
WAITING
WAITING
The 5 steps to Lean Thinking …
Implement Pull
Nothing is done by the upstream process until the downstream
customer signals the need
2 Map the
Value Stream
3Establish
Flow
4Implement
Pull
5Work to
Perfection
1Specify Value
Introduction to lean
Implement Pull• End customer initiates pull process
• Each step in the process takes the product it needs, when needed from the proceeding process
• Only the amount required is taken
• No action is taken until the downstream customer initiates it
supplier customer
One more please!Okay
Pull: Customer centric
For the most part, “Pull” comes naturally in a transactional environment – provided the customer is driving the activity.
The 5 steps to Lean Thinking …
Work to PerfectionThe complete elimination of waste so
all activities create value for the customer
2 Map the
Value Stream
3Establish
Flow
4Implement
Pull
5Work to
Perfection
1Specify Value
Introduction to lean
Perfection
• Perfect output • is delivered immediately• is defect free• is delivered one request at a time • is produced without waste
• Kaizen is the road to perfection… continuous improvement
months
days
hours
minutes
seconds
cycle time
Continuous Improvement Never Stops!
SPECIFY VALUE
Sunday’s Ice Cream Sundaes provides high quality, custom sundaes and a fun, social place to
enjoy them with friends!
EXAMPLE: Sunday’s Ice Cream Sundaes
MAP THE PROCESS
Wait for customer to decide on order
Take order
Call customer’s name
Process payment
Make sundae
Give Sundae to Customer
Call name again
Sundae melted
Order wrong
ESTABLISH FLOW
• Where wait can be reduced/eliminated
• How to re-purpose staff and layout of ice
cream parlor to maximize flow
IMPLEMENT PULL
• Use online ordering and inventory technology to ensure no excess materials ordered,
preparation of product in response to order
• Measuring tools to ensure correct amount of material used each time
WORK TO PERFECTION
Continue to monitor key metrics to ensure continuous improvement, waste reduction, and
customer satisfaction!
Issues:Waste
Melted sundaes if customer does not hear name called, incorrect orders, dropped sundaes as customer tries to find tableWait time
Long line at order counter, crowding at pickup window, long wait for sundae to be made
Solutions:• Online ordering – pre-payment and more accurate orders, fewer cashiers and more
sundae-makers• Table delivery – no melted sundaes and no line at pickup window• Online menu/more menus in-store--reduce wait time at counter• Store inventory system tracking to suggest supply re-order timing and volume
Sunday’s Basic Process:
WAITING
WAITING
WAITING
WASTE
Importance of Lean for You!
• Lean can be applied to anything – your process for making coffee, your routine for completing school work, etc.
•The more you think about and practice Lean, the more you’ll begin to see opportunities for process improvement in manyareas of work and life.
•Regardless of where your career and life take you, Lean canhelp you approach challenges efficiently and effectively!