tips for launching a successful lean journey -...

Tips for launching a

successful LEAN journey February 10th, 2017

Ian Marshall – Lean Champion

Canadian Manufacturers & Exporters

LEAN Definition

“LEAN is an Operations’

Strategy with a new set

of Values to Engage

People in Continuous

Improvement” Jeffrey Liker, author of The Toyota Way

Ian Marshall – Canadian Manufacturers & Exporters

https://www.google.ca/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwigoLze9v7RAhUh7IMKHSVxBk4QjRwIBw&url=https://www.amazon.com/Toyota-Way-Management-Principles-Manufacturer/dp/0071392319&psig=AFQjCNHbt9xqEarE0kiLDpP-dXdryJLhJw&ust=1486589142055309

LEAN Transformation

“Managers must change from

the habitual focus on results to

a different and less obvious

focus on process”


David Mann, author of Creating a Lean Culture

http://www.google.ca/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&docid=LVCLuaiEiUaGKM&tbnid=gTm1RTsPQyJNUM:&ved=0CAYQjRw&url=http://www.vasavidegreecollege.com/contentcatsList.php?s_parentCatId=4&&ei=1Z4oU9nGIIjCrQHr4YH4AQ&psig=AFQjCNHdP7kjpwpJjQx71yseq-vJWwpbFw&ust=1395257356305763


https://www.google.ca/imgres?imgurl&imgrefurl=http://www.shutterstock.com/pic-100815319/stock-photo-process-word-in-magnifying-glass-business-background.html&h=0&w=0&tbnid=avRTo61iro07uM&tbnh=229&tbnw=220&zoom=1&docid=hNoOGjuFXnLuNM&hl=en&ei=HKEoU7ylIpS6qQHHyYGoBQ&ved=0CAIQsCUoAA

http://www.vasavidegreecollege.com/viewcontent.php?seqContentId=17&FormcontentcatsList_grid_Sorted=&FormcontentcatsList_grid_Sorting=&s_categoryName=&s_code=&s_parentCatId=4&s_status=&&Formviewcontent_Page=2


http://paulakers.net/books/2-second-lean-resources/2sl-our-top-lean-videos

Paul Akers – FastCap.com
















https://www.google.ca/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwi68YTd9f7RAhXB1IMKHbSHADEQjRwIBw&url=http://www.toolovation.co.uk/2_Second_Lean_Paul_A_Akers_p/bk.2sec.lean.mp3.htm&psig=AFQjCNHbQMrQBfShct6LO6lpvQ6rws29qA&ust=1486588973683119

• Communicate the “why”

• Create the environment

• Deliver results


Three things to consider…

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Communicate the “why”

Ian Marshall & Carrie Schroeder – Canadian Manufacturers & Exporters

Three key human motivators:

Autonomy e.g. ‘FedEx day’: one innovation day

per quarter or ‘genius hour’: one

innovation hour per week

Mastery Making progress in meaningful work

Purpose

It starts with the “why”…

Daniel Pink

Communicate the “why”


“Décor’s mission is to

create cabinets people

love, bring light to the

world and the community,

to build life into people’s

lives and to leave behind

more then we take”

Larry Dyke, President & CEO, Décor Cabinets

https://www.google.ca/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwj8uYuJ-_7RAhUhyoMKHV9PCkQQjRwIBw&url=http://decorcabinets.com/about-us&psig=AFQjCNH2AeX0cQm_k4Q3YpBfS3RJ0S4pUQ&ust=1486590435115953



• Deliver results



Create the environment

• Go See

• Ask Why

• Show Respect

Fujio Cho, Chairman of Toyota


Three keys to leadership:

https://www.google.ca/imgres?imgurl=http://images.thetruthaboutcars.com/2012/09/Fujio-Cho-Picture-courtesy-trucktrend.com_.jpg&imgrefurl=http://www.thetruthaboutcars.com/2012/09/now-its-personal-china-puts-down-toyota-chairman/&docid=0ckA6tLO2gnY5M&tbnid=UfflV0CvdByBEM:&w=750&h=469&ei=O8opU5fIBca62gXe5YH4CQ&ved=0CAIQxiAwAA&iact=c


“It’s better to ask the

right question, than

to give the right

answer”

“The moment you tell

someone to do

something, you take

away their

responsibility” John Shook, President Lean Enterprise Institute



Core Values: • People

• Customers

• Kaizen

Employee Expectations: • Tell the truth

• Be fair

• Try new ideas

• Ask why

• Keep your promise

• Do your share


Art Byrne, author of The LEAN Turnaround

https://www.google.ca/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiQ9oucgf_RAhVL6YMKHYx1CB0QjRwIBw&url=https://www.amazon.com/Lean-Turnaround-Business-Principles-Transform/dp/0071800670&bvm=bv.146094739,d.amc&psig=AFQjCNHp5X8HZTNFhdL8Gvhvut0g9nBJLQ&ust=1486592055761949

• Trust – give employees a voice

• Put people in control…unleash the power

• Clarify team purpose and strategy

– Make it visible

– Measure what matters

– 10 second rule

• Mindset drives capability

• Show appreciation…



Billy Taylor The Goodyear Tire & Rubber Company

https://www.google.ca/imgres?imgurl=http://i.ytimg.com/vi/5IS5BE1slM0/maxresdefault.jpg&imgrefurl=http://www.youtube.com/watch?v=5IS5BE1slM0&docid=29Zg_B9i9MlRgM&tbnid=BEfbS6cX0iOrOM:&w=1920&h=1080&ei=tzV3VLT5F7f9sASyyYKIDQ&ved=undefined&iact=c



LEAN Greenbelt Kaizen Blitz

Duxton Windows & Doors

CME LEAN Training:

• Intro to LEAN

• LEAN Yellowbelt

• LEAN Greenbelt

• LEAN Blackbelt

• LEAN for Leaders

• Training Within Industry



• Deliver results



Deliver results

“Begin with stability producing lean

projects and use them to prepare the

ground for lean management”





https://www.google.ca/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwi9q9PGgpbKAhVGOT4KHTpZCUkQjRwIBw&url=https://www.crcpress.com/Creating-a-Lean-Culture-Tools-to-Sustain-Lean-Conversions-Third-Edition/Mann/9781482243239&psig=AFQjCNGgNhjPYO02_xDmTEyhRRgzuMFs6A&ust=1452198345143039

Deliver results


Before After

LEAN Greenbelt two-day 5S Kaizen Blitz




Deliver results

Simple Material Replenishment Systems


Sales Engineering

Planning

Purchasing Production

Parts Assembly Paint

Finishing Shipping

C

a

s

h

Q

u

o

t

e

Deliver results

Deliver results


“Wherever there is a customer, there is always a value stream… your challenge is to see it”

Jim Womack – author of Lean Thinking

Bottlenecks

Cycle Time

Issue Root Cause Solution

Process Step

Deliver results


“Visual controls

connect people to

processes and reflect

adherence”


Hour By Hour Actual to Plan Progress Chart

“The status of virtually every process should

be visible in lean management”



Deliver results


Traditional management:

“Did you meet the

schedule?”

Lean management:

“What caused the problem

that interrupted the

process and who will do

what to fix it?” David Mann, author of Creating a Lean Culture

Daily Huddle – Shift Plan & CI



Deliver results

“The closer your position to

Production, the more time you should

spend watching the process”


Leaders Role:

- Establish the process

- Monitor adherence

- Improve the process






• Deliver results



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