October 26, 2011

The NEW Lean Consulting Group

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Small Business Seminar:

Lean for your small business

• NEW Lean Consulting Group– Provide Lean consulting services

– To community businesses and not for profits with a quality resource for their Lean journey.

• Certified Lean Lead Facilitators– Jamie Voster

– Lisa Rothbauer

– Amy Lauko – Project Lead

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Welcome and Introductions

• Cutting time to process customer requests by 75%

• Reducing inventory by 75%

• Improving quality by 50% – 200%

• Increasing productivity by 50% – 75%

• Reducing clutter

• Reducing time it takes to find and do things

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Imagine……….

Lean -

A business system involving all employees

which constantly pursues the elimination of

waste to shorten the lead time of a process.

Not just for manufacturing! Lean principles

can be applied to any business and every

process.

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Is Is Not

• A significant shift in

thinking and performance

• A long term strategy

• Applicable to any

organization and every

process

• Focused on maximizing

value

– optimizing flow

• Culture changing

• A headcount reduction

strategy

• Merely a cost reduction

strategy

• A quick, one time fix

• A short term project

• Applicable only to

manufacturing

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Lean Is…. Lean Is Not

Learning to see

Focus on process not on people

Standard work

Continuous improvement

One piece flow

Error proofing (poka yoke)

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Elements of Lean Thinking

Setup Reductions

Teams5S

Error Proofing

TPM

Kanban

Work Cell

A3 Problem Solving

Value Stream Map

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Lean Toolbox

• Change is required in

– Thought

– Culture

– Perspective

• Change must occur to achieve success.

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Lean Requires Change

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Change is hard……...

But stagnation is fatal.

Dr. Peter Bishop

University of Houston

Critical success factors:

• Leading

• Training

• Acting

• Sustaining

• Plan, Do, Check, Act (PDCA)

Implementing Change

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Kaizen -

Japanese for improvement or

change for the better.

It refers to a philosophy or practice that

focuses upon continuous process

improvement.

• Cross functional team empowered to make rapid

changes in a process

• Targets waste, variability, and non-value add activity

• All necessary resources are readily available

• Look for immediate results that address root cause.

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Kaizen Events

Standardize

I

M

P

R

O

V

E

M

E

N

T

TIME

Kaiz

en

Ka

ize

n

Ka

ize

nFrom “Kaizen”, Masaaki Imai

Standardize

Standardize

Ka

ize

n

Starting Process

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Continuous Steady Improvements

via Kaizen Events

An insatiable drive to increase value through

the on-going elimination of waste.

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Key Characteristics of a Lean Team

The focus of Lean is…

waste elimination.

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Waste

Anything other than the minimum

resources required to add value to an

end product or service.

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What is Waste?

Motion

Waiting

Transport

CorrectionOver-Processing

Over-Production

Inventory

Knowledge

VALUE ADDED WORK

5%

1

2

3

456

7

8

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Waste Wheel

Waste in the Office

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Types of Waste Business Process Waste

Motion Walking, routing information

Waiting Delays and queues, decision making

Transportation Information hand-offs

Correction Defects, re-work, incomplete data

Processing Unnecessary steps, variation of methods

Overproduction Unnecessary reports and information

Inventory A task waiting to be started (inbox)

Knowledge Untapped skills and experience, routine non-value

adding activities

• Sieri - Sort

• Seiton - Straighten

• Seiso - Shine

• Seiketsu - Standardize

• Shitsuke - Sustain

• = 5S

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Introduction to 5s

• Sort: removing the unnecessary

• Straighten: a place for everything

• Shine: clean up, fix up

• Standardize: everything is consistent

• Sustain: maintain, review standards

= 5S

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5s

5SBefore After

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• A one page visual representation showing the flow of

all processes, information and material

• Current state analysis (snap shot) shows

– All current value added and non-value added

processes

• Future state analysis shows

– Improved value added processes and eliminates as

much non-value added work as possible

• Action plan for target state implementation

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Introduction to

Value Stream Mapping (VSM)

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Getting the right things to the right place at the right time in the right quantity to achieve perfect work flow, while minimizing waste and being flexible and able to change.

• Reduced waste, costs, and lost opportunities

• Increased• Efficiencies• Ability to serve more customers in the same time• Customer satisfaction• Timely customer access to goods and services• Quality• Employee empowerment

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Benefits of Lean

Who have we helped Change?

• Housing Partnership

• Medical Facility/Retirement Home

• Temperature Controls Solution Provider

• Organic American Apparel Company

• Collision Repair Shop

• Public Library

• Counseling Services Company

• Homeless Shelter

• Home Care Provider25

We can help with:

• I need more help, I’m just too busy to keep up.

• I will start fixing it once I find my tool.

• I’m overwhelmed and don’t know where to start

• I’m too busy to train employees.

• There must be an easier way, but how?

• Everyone has their own way of getting it done.

• I can’t find the part so express order a new one.

• There are not enough hours in the day.

If we don’t change

we will end up

where we are headed…

Chinese Proverb

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Are you ready to Change?

• Contact NEW Lean

• Identify your problem/pain (1-3 focus areas)

• Establish goals ex: (reduce wait list by 50%)

• Develop Plan

• Identify Resources

• Schedule your Event

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