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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 seeFocus on process not on peopleStandard workContinuous improvementOne piece flowError proofing (poka yoke)
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Elements of Lean Thinking
LEAN Principles
Setup Reductions
Teams 5S
Error Proofing
TPM
Kanban
Work Cell
Standardized
Work
Kaizen
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 BishopUniversity 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
IMPROVEMENT
TIME
Ka
ize
n
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 WORK5%
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345
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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
5S Before 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 Provider 25
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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Contact:
• Amy Lauko [email protected]
• Lisa Rothbauer - [email protected]
• Jamie Voster [email protected]
• NEW Lean – newlean.org
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