Lean Tools and Processes
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The document discusses the application of lean tools and processes across various industries to eliminate waste and improve efficiency. Key concepts include value stream mapping, gemba walks, 5s organization, standard work, poka yoke for error proofing, and kaizen for continuous improvement. It emphasizes that lean is a mindset and a journey, not merely a training session, encouraging businesses to adopt these principles.
Lean Tools and Processes
- 1. Lean Tools and Processes: How to Use Them in Your Business Dale B. Wilen, PMP ©2013 International Institute for Learning, Inc., All rights reserved.
- 2. Dale Wilen Senior Consultant – IIL Distinguished Faculty – City University School of Business BSME – South Dakota School of Mines & Technology MAEd – University of Phoenix PMP Certified LSS Master Black Belt
- 3. The Lean Evolution Lean began in manufacturing The values and principles of Lean are now recognized In the “back offices” and across industries – from medical to retail Leaders are “thinking Lean” “Business as usual” is probably inefficient and wasteful Let’s discuss how you can use these ideas in your business
- 4. How can you apply Lean to your business? What do you want to accomplish? Cycle time reduction – whether in manufacturing or in the back offices? Eliminating waste – excess inventory, motion, transportation? Remove non-value added steps in processes? Error proof your activities, products, and services? Define and use best practices?
- 5. Traditional Lean Tools Value Stream Mapping Gemba Walks 5S Standard work Poka Yoke / Error proofing Kaizen events
- 6. Value Stream Mapping – Finding Opportunities VSM is a visual tool, depicting the flow of material or information VSM is used to understand the processes of your business VSM can be a plan to get from a “current state” to a “future state” VSM by itself does not fix anything! (That’s often misunderstood.) VSM makes visible opportunities and problem areas Once identified, the problem areas are addressed with other tools
- 7. Gemba/Genba Walks – Observe the Workplace “Genba” is the place where value is created A Gemba walk is going there, looking for waste and opportunity Management or the workforce should conduct these activities “Fresh eyes” is often a good tactic to employ Whether in an office or a factory, you can observe Work in progress, wasted motion, confusion/disorganization
- 8. 5S – Organizing the Workplace 5 Japanese words – Seiri; Seiton; Seiso; Seiketsu; Shitsuke 5 English words – Sort; Sweep; Simplify; Standardize; Sustain 5S reduces clutter and confusion 5S improves the working environment 5S is effective in every type of workplace
- 9. 5S in the Shop Organized tools makes them easy to find when needed Standard tool locations make it easy to see if a tool is missing Hazards are removed when things are in their place Benefits: Increased safety Time savings are realized when the right things are in the right places Morale is improved in a clean workplace
- 10. 5S in the Office How many office supplies do you have? Can you always find things when you need them? Do you have duplicated resources in the office? Is your office organized such that you work efficiently? Let me tell you about an office that needed to be “5S’d”…
- 11. Standard Work – Find the Best Practices Simply put, standard work is using best practices It is NOT asking your employees to become robots! The employees (the users) determine the best practices Standard work removes variation in methods, tooling, and practices Standard work can be applied in the shop or in the office Let me tell you how NOT to do standardization…
- 12. Standard Work – Why Should You Do It? Why should you observe standard operations? It’s the best method; it’s the proven method; it’s the law! Standard work locks in improvements Many times improvements are lost by “backsliding” Standard work helps to “Maintain the Gain” Standard work consists of three elements: Takt time; work sequence; and standard work in process
- 13. Poka Yoke – Make It Hard to Do It Wrong “It is good to do things right the first time; it is even better to make it impossible to do it wrong the first time.” Errors cause defects – and drive costs up Errors may be caught by inspection – but not always When humans are involved, there will inevitably be errors Errors can be prevented – or warnings can be given Error proofing should be simple and cheap
- 14. Kaizen – Improve the Process Kaizen simply means “good change” Any improvement activity might be thought of as a Kaizen In Lean, a Kaizen event is often in the form of a workshop These workshops are usually nimble and fast paced They are a great method to use in urgent situations
- 15. That was Just Touching the Surface… Obviously, there is much more to discuss regarding these tools These are just a few of the tools that can help “Lean” your business Some of the tools and approaches you’ve known all along They are common-sense approaches that are logical and easy to use Lean is a journey and a mindset, not just a class or seminar!
- 16. Questions?
- 17. Intelligence – Integrity – Innovation We invite you to take a closer look at what we can accomplish together. Please visit iil.com or contact learning@iil.com to learn more about our training, consulting, coaching, customized courses and other pathways for professional development. Connect with Us: facebook.com/IIL.Inc @IILGlobal bit.ly/IILlinkedin ©2013 International Institute for Learning, Inc., All rights reserved. bit.ly/IILgoogle youtube.com/IILGlobal allpm.com