Introduction to Lean Web Presentation.pdf

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© Copyright 2010 EMC Corporation. All rights reserved.
Lean Basics Overview
EMC
2011 Training
NCDENR April 2011

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Topics
• Lean Six Sigma defined
• Why Lean Six Sigma?
• What’s a process?
• Interrogating the process by identifying Value & Waste
• Brief overview of some tools that identify Waste
• Key principles of Lean Thinking: Flow & Pull
• Brief overview of some tools that help eliminate Waste
• Next steps

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Lean
• Process improvement methodology targeting the
elimination of waste – any human activity that absorbs
resources but creates no value.
• Lean Thinking is the method used to combat waste
– Pioneered by the Toyota company in Japan after WWII.
– Application of Lean in Manufacturing has led to much cost
removal via the elimination of wasteful efforts.
– Lean Thinking provides for change that allows you to do more with
less while coming closer to providing customers with what they
really want.
• Lean concepts can easily be used in other business
applications and is not just beneficial to
manufacturing

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So what is LEAN?
Simplify the
process
 Identification of value and elimination of waste to
improve the process.
Key Lean
Performance Goals
 On-demand: when the customer wants it
 Defect-free: how the customer wants it
 One-by-one: exactly the quantity the customer
wants
 Lowest total cost: business cost for you and the
customer
Key Principles of
Lean Thinking
 Value: what customers are willing to pay for
 Value Stream: all the steps in our processes that
deliver value to our customers
 Flow: organizing the Value Stream to be
continuous
 Pull: responding to downstream customer demand
 Perfection: relentless continuous improvement
culture; A continuous journey

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Six Sigma
• Business management strategy developed by Motorola in
the 1980’s.
• Seeks to improve the quality of processes by
identifying and removing causes of defects and
minimizing variability within in process.
• Six Sigma is a statistical term indicating a high level of
quality
– 99.99966% of the products are expected to be free of defects
– Can also be stated as 3.4 defects per million
• Six Sigma tools and concepts can easily be used in
other business applications and is not just beneficial
to manufacturing.

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What is Six Sigma?
Level of Process
Performance
 3.4 Defects per Million Opportunities
Philosophy
 Executive Ownership
 Business Profitability & Customer Satisfaction
– Moving the Mean
– Variation Reduction
 Data-based decisions
 Hard, Soft and Strategic Benefits
Consistent,
Rigorous Approach
to Problem
Solving
 Define
 Measure
 Analyze
 Improve
 Control
The right people working a well scoped problem
Clearly understand and measure the “As Is” Process
Analyze failure modes to understand the causes and effects
Experiment with and improve process based on data
Monitor critical outputs to prevent repeat failure

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Why Lean Six Sigma?
Drives down costs by eliminating waste and process variability
N (Simplify)
NE (Simplify & Control)
E (Control)
Lean
Six Sigma

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• A structured problem solving methodology used to:
– Define (Scope)
• Get the right people on a well scoped problem
• Set a SMART goal on what’s critical to the customer
• SMART? Specific, Measurable, Achievable, Relevant, Time-
bound
– Measure (Baseline)
–“As Is” process around the problem
– Data, variation not just the average
– Analyze (Cause &Effect)
• Drives cause and effect conversations around the “As Is” process
• Look for variation in the critical metric throughout the process
• Look for waste with Lean tools
• Prioritizes where to work
Lean Six Sigma …combines the strengths of both
approaches

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Lean Six Sigma …combines the strengths of both
approaches
 Structured problem solving methodology continued:
– Improve (Communication)
• Improves the process based on waste removal and mistake
proofing
• Improves the process based on data
– Control (Control Plan)
• Develop a control plan to maintain the gains and have an early
warning system on the critical metric

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How does Lean Six Sigma help us compete?
• Profit = Price – Cost
– Price controlled by market
– Cost controlled by the seller
• Greatest competitive edge is
cost reduction
• Reduce cost by Waste
elimination
– those things customers do not
want or need
• Reduce cost and improve
quality by removing Variability
• Increase customer satisfaction
at lower costs by:
– identifying their needs (values)
– eliminating process variation
– providing what the customer
needs when they need it

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Any questions about
Lean,
Six Sigma, or
Lean Six Sigma?

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Process improvement requires that we know our
process …what’s a process?
• A set of common tasks that creates a product, service, or
plan that will satisfy a customer or group of customers.
– Processes can have “internal” customers and “external” customers
• A sequential series of steps leading to a desired outcome
If you can't describe what you are doing as a
process,
you don't know what you're doing.
W. Edwards Deming

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What’s a great tool that we can use to get an overview
of a process in just 1 page?
Process
(Activity)
Name
Process
Input* Output*
* Input and Output Variables that are Measurable
Input
Input
Input
Input
Input
Input
Output
Output
Output
Output
Output
Output
IPO Chart

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Any questions about
what’s a process?
IPOs?

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Interrogate the process
• Where’s the Value?
• Where’s the Waste?

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• Value Add
– Customer believes it is important; willing to pay for this task
– Physically changes the thing adding desired function, form, or feature
– Work is done right the first time
• Non-Value Add
– Task adds no value as viewed by the customer
– Examples include: correcting/reworking, expediting, multiple
signatures, counting, handling, inspecting, set up time, downtime,
transporting, moving, delaying, storing…etc.
• Necessary Non Value Add
– Process would break down if this task was not performed
– Required by law or regulation
– Task reduces financial risk
Value

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Truths About Seeing Waste
• WASTE isn’t a judgment on how well people work; it exists
in all processes
– Processes are wasteful, people are not
– Don’t take it personally; let’s improve the processes
• Our solutions have to eliminate waste
– Waste elimination improves performance
– Improved performance creates secure companies
– Secure companies create secure Jobs
• As we learn to see waste, we need to work on not being
judgmental about it
It is what it is… and it wasn't created
intentionally

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Transportation:
Physical movement
of materials or work
from where it was
produced to where
it is needed
Defining Value – Seeing the Waste

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Inventory:
Any excess material
within a process
that the customer
does not want or
need based on
actual demand

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Motion without productivity:
If motion is part of the process and not used to add value,
it is waste

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Waiting:
People or parts that wait
for a work cycle to be
completed

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Over-production:
Producing items for which there are no true customer orders or
more work than the next operation needs or can absorb

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Over-processing:
Any non-value added activity
that customers neither want,
request or will pay for…

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Defects:
A defect is a component
or unit which the customer
would deem unacceptable

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Safety Risks are a Waste
Safety risks are in processes that
enable injuries to happen in the
workplace.
Injuries cost through:
• lost work days
• higher insurance costs
• product delivery delays
• slowing the process

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8 Forms of Waste (TIMWOODS)
Waste
Category
Production
Example
Administration
Example
Transportation
Excesses
Moving material between disjointed
production stages in separate locations
Walking around to get approval
signatures on a travel authorization
Inventory
Build-up
Large WIP (work in progress) inventory
during production stages
Multiple copies of a document stored in
every desk
Motion
Without
Productivity
Operator must bend over to pick up
circuit board to start production sequence
Looking for poorly filed documents by
searching every filing cabinet
Waiting
for
Materials
Waiting for raw material replenishment to
begin production setup
Waiting for approval signature of a
document
Over
Production
Producing more than production schedule
requirements
Generating project status reports that are
not reviewed or used
Over
Processing
Reworking of defective components from
the first stage of production
Capital projects plans needing reviews
and signatures from 18 people
Defects
Producing one bad unit out of 10 during
final assembly
An inaccurate report that must be redone
due to incorrect information
Safety
Risks
Injuries that result in personal suffering,
lost work days, increase insurance costs
and delays in product delivery
Injuries that result in personal suffering,
lost work days, increase insurance costs
and delays in product delivery

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Any questions about
Value?
Waste?

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What tools identify waste?
Tools to Identify Waste
Strategic Tool Waste Identified
Value Stream mapping Inventory, Over production
Takt time Inventory, Over production, Waiting
Spaghetti diagram Transportation, Motion
Time Observations
Waiting, Motion, Transportation, Over processing, Defects,
Inventory, Over production
Flow Charts Over processing, Motion, Transportation
Load Charts Waiting
Standard work sheets
Defects, Inventory, Over production, Waiting,
Transportation, Over processing
Production Control Boards Defects, Inventory, Over production, Waiting

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Read the cookie
recipe
Get the needed
ingredients from
the fridge &
cabinets
Get the needed
bowls, spoons,
measuring tools
Follow the recipe
step by step & mix
the cookie dough
is oven
required?
if yes, preheat
oven to
temperature stated
in recipe
Shape the cookies
& place on cookie
tray
Place in oven &
cook for the
amount of time
stated in recipe.
Remove from the
oven & allow to
cool
Eat them all up!
Cookie Making Process
If no, continue to
follow instructions
Tools to Understand the Process plus Identify Waste

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Flow Charts/Process Flow Diagram
• Definition: a diagram commonly used to indicate the general
flow of processes
• Can be completed at different levels, or in different styles
• Uses:
– preparation for a time
study
– identify VA/NVA/NNVA
– look for flow & missing
steps
– see the waste

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Value Stream
• A value stream is a series of all actions required to fulfill
a customer's request, both value added and not. A value
stream contains a product or a family of products that
have similar material and information flows. ...
www.gemba.com/resources.cfm
• Including:
– Information flow
– Material flow
– Inventory (WIP)
– Value Add and Non Value Add activities
– Transportation flow
• A company will have multiple value streams

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Value Stream Maps (VSM)
• A VSM combines:
– Process Flow
– Information Flow
– Transportation Flow
– Inventory Balances
– Cycle Times
• VSMs make it easy to see:
– Improvement Opportunities
– Excessive Inventory
• VSMs highlight:
– Total Inventory
– Total Process Time
– Inventory Days of Supply
• VSMs display the entire value-delivery system

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Sample of a Value Stream Map in
Manufacturing
6 Days
Pre-ESS 1 Mcs ESS – 6 Mcs
I
_240_ pcs
62 Min
I
_60_ pcs
2.1 Days
378 Min
XPE Cell – 0 Mcs
I
_450_ pcs
7.8 Days
443 Min
Bottleneck
Operation
Yield = 91%
2 shifts
C/O = 180 sec
C/T = 420 MIN
Batch = 4
DGR = 50 Brds/Day
CPK – 0 Mcs
Yield = 99%
2 shifts
C/O = 0
C/T = 20 MIN
Batch = 1 order
DGR = 10 Brds/Day
Yield = 91%
3 Shifts
C/O = 1090 sec
C/T = 360 MIN
Batch = 2,4,6, or 8
DGR = 60 Brds/Day
Yield = 85%
3 shifts
C/O = 103-133 sec
C/T = 60 MIN
Batch = 1 - 12
DGR = 60 Brds/Day
I
20_ pcs
REWORK
_64 pcs

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Marketing
Vision Doc
Initial Eng
Estimates
Marketing
Requirements
Project
Planning
Development
Code
“Freeze” QA
Final QA
Code Deploy-
ment
Customer
Specifies
Changes
Code
Changes
Customer
Approves
Changes
Deploy
2 wks
1 wk 4 wks 4 wks 8 wks 6 wks 2 wks
1 wk
2 wks
2 wks
1 day
2 wks 2 wks
0 time 0 time 0 time 4 wks
0 time
0 time
4 wks
0 time
Work
Wait
44 wks + 1 day total process time
of which 12 wks is wait time
Value Stream Map – Software Development
* From Kent Beck,
Lean Software Development
by Mary & Tom Poppendieck

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Takt Time
• Takt Time is the required pace of production to meet an
average customer demand rate
 Available Time = 7 hrs or 420 minutes
 Customer Demand per Day = 840 item
Must produce 1 item every .5 minutes
to meet customer demand rate
Takt Time =
Available Time/Day
Customer Demand/Day
Takt Time =
420 min
840 item

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Spaghetti Diagram
Before After
Parts Traffic Dist. = 214 ft
Walking Dist. = 431 ft
Parts Traffic Dist. = 139 ft
Walking Dist. = 292 ft

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Any questions about
these tools that help
identify waste plus
understand your
process?

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Key Principles of Lean Thinking:
FLOW - Organize the Value Stream to be
Continuous
• Objective is for materials to flow non-stop until it gets to the
customer
– Delays or wait times increase the time for delivery and create waste
• May require a new Layout
– Value-adding steps are arranged one after the other
– Shrink physical footprint of area to avoid inventory piles
– Product moves via the most direct route
• Work must be balanced amongst workers so items flow
“non-stop”
Lean Philosophies to Eliminate Waste

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Flow

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Key Principles of Lean Thinking:
PULL - Responding to Downstream Customer
Demand
• Pull: Producing goods based on actual consumption
– Process steps in the Value Stream are linked via Pull replenishment
– No one upstream process produces until the customer downstream
signals for it
• Push: Producing goods to a forecast or demand schedule
– Not linked directly to actual customer demand consumption
– Often requires managing separate production schedules at multiple
points in the process
– Will lead to all forms of Waste – TIM WOODS
Push is not LEAN. Pull is the desired LEAN Process Method

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What tools help eliminate waste?
Tools to Eliminate Waste
Strategic Tool Waste Eliminated
Cellular Manufacturing Waiting, Motion, Transportation, Over processing,
Defects, Inventory, Over production
Kanbans Impact of Defects, Inventory, Over production,
Waiting, Transportation
SMED (Single Minute Exchange of
Dies)
Waiting, Motion, Over processing, Defects, Inventory,
Over production
5S Defects, Inventory, Over processing, Motion,
Transportation, Over Production
Visual Management Waiting, Motion, Defects
Jidoka (Automation with a human mind)
/ Poka-Yoke (Error proofing)
Defects, Inventory, Over processing
Kaizen Waiting & all other forms of waste can be addressed

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Cellular Manufacturing
• Cellular manufacturing definition:
– Machines / operations / process steps are placed side by side with
minimal inventory between
– Continuous flow
• Cell layouts are more robust to machine breakdowns, have
common jigs and fixtures in the same area and support high
levels of differentiation
• Grouped together according to the families of parts
produced
• Advantage: Material flow is significantly improved which
reduces
– distance travelled by materials
– inventory
– cumulative lead times
Waste eliminated: Transportation, Inventory, Motion, Waiting, Over processing,
Overproduction, Defects

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Principles of Cellular Manufacturing
• Key components
– Continuous flow/single piece flow*
– Standard work (the one best way)
– Typically product specific
– Utilizes kanbans
– Employs 5S and visual management
– “U” shaped layout (minimizes people and parts movement)
– Runs on Takt Time
– Standard WIP (work in progress)
* Single piece doesn’t always = 1

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Kanban and Kanban System
• Kanban in Japanese means “card” or “sign”
– Visual tool used to achieve JIT (just in time) production
• Kanban is established using fixed quantity bins, containers,
or pallets that are produced in an agreed replenishment time
• Kanban Systems can provide direct communication between
our customers, through our work cells, and out to our
Supplier/Partner
• Kanban Systems have less dependency on forecasts for
driving receipts of materials – replace only what is used
Waste eliminated: Impact of Defects, Inventory, Overproduction, Waiting, Transportation

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Look familiar?

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• Sort – When was this last used?
• Set in Order – get organized!
• Shine – keep it clean!
• Standardize – take ownership!
• Sustain – keep it up!
What is 5S?

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How is 5S implemented?
• Identify the area to be improved
– Set bounds and scope work
• Red Tag everything not needed in that area
– Move to designated location
• Prioritize items frequently used
– Organize to minimize wasted motion
• Clean what remains
• Set standards and assign responsibilities
– Take pride in ownership – what accomplishment!

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5S - Visual Management

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What is Kaizen?
• KAI = Change Zen = Good (for the better)
– Japanese word for continuous improvement in small, incremental
steps
• A Kaizen Event is …
– a “Tool” from Lean methodology
– targeted at the improvement or creation of a specific process
– up to a week in a very focused, structured team environment
– working together to rapidly implement change initiatives to quickly
realize benefits
– an application of continuous improvement
• Lean has a foundation built on the concept of continuous
improvement; Kaizen helps to accelerate change

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Any questions
about the
philosophies or
tools used to
remove waste?

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Lean Basics – Key Points
• Lean is a process improvement methodology used to combat
waste.
• It can be used with Six Sigma which helps us remove
variation from a process.
• Everything is a process; every process can be improved.
• Only our customers can define value. Everything else is
waste and should be eliminated as possible.
• In order to remove the waste in our process, we must be able
to see it…Lean provides the needed tools.

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Lean Basics – Key Points
• Key components of Lean include:
– Pull
– Cellular Manufacturing
– Continuous Flow / Single Piece Flow
– Standard Work
• Kaizen is the tool that can take us from our current state to
where we want to be quickly.
• Continuous Improvement is essential to success in all Lean
programs.

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Are you ready to begin
your Lean Journey?
Final Questions & Next Steps
Available for mentoring:
Lee Ann Parrott
EMC Corporation
(919) 387-5380
leeann.parrott@emc.com

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References to check out
• Read:
– Lean Six Sigma by Michael L. George
– Lean Six Sigma for Service by Michael L. George
– Lean Solutions, How Companies and Customers Can
Create Value and Wealth Together by James P.
Womack & Daniel T.Jones
• Check out these web sites:
– www.isixsigma.com
– www.lean.org

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Thank you!

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