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Purdue Research Foundation©1
Where Does The Lean Revolution Start?
Mark K. Clare, MS, MA, LSSMBB, LSC
Principal, Strategic Initiatives Purdue University
West Lafayette, IndianaOffice (765) 496-694, Mobile (260) 433-7923
Purdue Research Foundation©2
AGENDA
Your Lean Experience Transformation Strategies Building Blocks Lean Daily Improvement The Need for Frugal Engineering Current Work at PHA
Level Set
How long have you been working with lean?
What results and issues have you seen?
Purdue Research Foundation©3
From Tools to Transformation
Lean Transformation
1 .Tools
2. Management Model
3. Culture
A way to improve
How we run things
How we do things
Years
Lean
A management philosophy and improvement toolkit dedicated to creating customer value by continuously eliminating waste and enhancing flow.
Purdue Research Foundation©4
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Strategy Workshop
Target Value Stream (VS)
Series of Rapid Improvement Events (RIE)
Daily Improvements
REFRESH
REFRESH
Lean Leader Training Business Assessment Identify Value Streams Prioritize
Lean Training VS Analysis Event Initiate VS Management
Lean Training RIE Preparation RIE Delivery Daily Improvement Troubleshoot & Close RIE
Management Meeting
Target Metric
Setup Lean Daily Improvement
Daily Improvements
REFRESH
REFRESH
Department Needs Identify Metrics Prioritize Set Goal
Lean Training Establish Baseline Numeric Goal
Lean Training Data Collection Process Visual Management
Collect and Post Data Visual Control Huddle & Problem Solve Implement Just Do Its
Collect and Post Data Visual Control Huddle & Problem Solve Implement Just Do Its
Top Down Bottom Up
Transformation Strategies
Middle Out – Not Shown• 1 Project• 10 Rapid Events• 1000 Daily
Improvements
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Lean Daily Improvement (LDI)
Getting Started with LDI
1. Pick metric2. Establish baseline and goal3. Define data capture process4. Create graphs and forms5. Set up board6. Brief/train team and hold
initial huddle7. Start data collection and
daily huddles
PDCA
• 1 Project• 10 Rapid Events• 1000 Daily
Improvements
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LDI as Engine of Lean Revolution for CAHs
LDI = Lean Daily Improvement
Using a Bottom Up approach is cheaper and faster but it can run into trouble as you scale Middle managers are not comfortable
with team problem solving RIEs are hard to facilitate to closure
because they don’t have the support of a value stream management model
Need to inject a lite version of key elements from the Top Down approach to help LDI scale
“Lean healthcare will only come of age when we have a simple do-it-yourself method that smaller hospitals and clinics can follow on their own with minimal mentoring from experienced advisors.” http://www.planet-lean.com/
Dan Jones, global lean expert and author of The Machine that Changed the World
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Rapid Improvement Events (RIE)
4 -5 day event 3 day event
Strategy Workshop & VS Analysis
Event
7 days 2 days
PHA Frugal Engineering
In 2015 15 of Indiana’s Critical Access and Rural
Hospitals improved process with frugal RIEs
14 of Indiana’s Critical Access and Rural Hospitals have signed up for a 3 year
lean transformation!
We are currently using micro-learning to frugally engineer all of our training and certification offerings to reduce time and cost of developing lean skills
Frugal Engineering
Less Please!!
Products and Services in advanced economies are generally feature fat. (= waste)
Give me the 20% of the features that deliver 80% of the value for a fraction of the cost.
