Additional Lean Tools

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• Additional Lean Tools
• For
• Bend-The-Curve

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Additional Lean Tools For Bend-The-Curve

• Purpose
• Link new tools to previously learned tools.
• Have a shared understanding of four (4) new tool.
• Provide space to experience using these new
  tools.

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Additional Lean Tools For Bend-The-Curve

• AGENDA
• Review current tools
• Define new tools
• Explore tool use
• Practice tool application

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The Predominate Lean Tools used To Date

• Value Stream Mapping
• Kaizen

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The Predominate Lean Tools used To Date

• Value Stream Mapping (VSM)
• VSM is a deliberate, methodical method used to
  assist VSM Teams in visualizing and
  communicating how their processes (aka value
  streams) currently functions.1
• This establishes the Current State.

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The Predominate Lean Tools used To Date

• Kaizen 2
• kai to take apart
• zen to make good
• Bottom line Continuous Improvement

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Lean Tools Suite 3
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TODAYS FOCUS

• STANDARDIZATION
• THE 5 S
• VISUAL CONTROL
• 5 WHYS

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THE LEAN TOOL SUITEand THE RELATION TO
PROCESS-MIND-SET.
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A Foundationto Lean Tool

• Process mind-set
• Know the customer
• All wok is a process
• Problem happen for a reason
• Continuous improvement

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WHAT IS A PROCESS? 4

• A process is a combination of
• people, resources and methods
• which produce a result.
• Processes transforms inputs
• into outputs

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WHAT IS A MIND-SET? 5
A state of mind A way of thinking An approach An
outlook (even) An attitude How we frame things! A
way of being
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All Work Is A Process

• Processes can be defined
• All processes have customers
• Recipient of output
• Internally, the next step in the process
• Customer needs are definable
• Process (and steps) are measurable
• Process can be adjusted to satisfy the customer

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Problems Happen For A Reason

• There is a root cause for every problem
• We must find the root cause to create meaningful,
  lasting improvement.

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The Customer

• Know The Customer
• Who they are
• External
• Internal
• Know What The Customer Wants

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Continuous Improvement

• A WAY OF BEING, THINKING, ACTING AND KNOWING
• Everything can be improved
• What is measured tends to improve
• Improvements can be accumulated
• Based on knowledge of cause
• Become built-in
• What is Visible is maintained in a state of
  readiness

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Lean Tools Suite
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STANDARDIZED WORK 6

• WHAT IS A STANDARD?
• A standard is a rule or example that provides
  clear expectations
• Standards consistently communicated, applied, and
  documented to enables
• consistency

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STANDARDIZED WORK

• Standards are established
• using factual or observed
• Best Practices

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STANDARDIZED WORK

• STANDARDIZED WORK
• An agreed-upon set of work practices that
  establish the best and most reliable methods and
  sequences for each process and each Direct Value
  Stream Participant (aka employee) in that
  process, or value stream.

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STANDARDIZED WORK

• Doing the work all the same way limits my
  creativity.
• I deal with people not machines. Therefore, I
  must be flexible.

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STANDARDIZED WORK

• TASK in 7 minutes
• Turn to the person to your left and
• Come up with two (2) answers to this question
• How is creativity and flexibility maintained in a
  standardized workplace?

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STANDARDIZED WORK

• BENEFITS?
• Cost decrease Fewer mistakes or errors are made
• Lead Time is decreases The process becomes more
  reliable
• Quality Assurance costs decrease Quality is
  built into each step reducing or eliminating the
  need for inspections downstream

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STANDARDIZED WORK

• Customer complaints decrease
• quality standards and schedules are
• met more consistently.
• Process become more efficient and Reliable.
• Employee skills and morale increase.
• Anyone, from novice to veteran is
• easier and clearer, and boosts
• enthusiasm, self confidence and skill.

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STANDARDIZED WORK

• TASKtake _____ minutes
• In your VSM Teams, discuss with Team members
• opportunities apply, or farther standardization
• Challenges to applying standardization
• What assumptions are you making?
• Reach a decision about what your Team will do to
  apply these learnings.

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Lean Tools Suite
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5S SYSTEM 7

• The 5 pillars of 5S are defined as
• Sort
• Set-In-Order
• Shine
• Standardize
• Sustain

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5S SYSTEM

• WHAT IS 5S? i a highly effective set of
  techniques that remove waste from the work
  environment - the desktops, office spaces,
  storage,files, etc. - through better workplace
  organization, visual communication and general
  cleanliness.

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5S SYSTEM

• Benefits of 5S
• Neat, clean work environments are
• highly productive
• safe places to work 
• Less prone to make mistakes
• Generally better places to work

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5S SYSTEM

• Sort
•      Clearly distinguish the items needed
• in a work area from those no longer
• needed. Red tag items that are
• unneeded.

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5S SYSTEM

• Set in Order Keep the needed items in their
  correct place to allow for easy and immediate
  retrieval.
• Shine Clean everything, inside and out. Keep
  work areas, all work surfaces and equipment clean
  and free from clutter, excess materials and
  tools, etc

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Who Owns This Drawer?
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Is This Familiar?
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Is This Familiar?
BEFORE
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Is This Familiar?
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5S SYSTEM

• TASKtake 15 minutes
• In your VSM Team, come up with at least three
  (3) ways in which your Team will apply the 3 S
  thus far discussed as a means of continuing to
  improve your Teams Value Stream..

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5S SYSTEM

• Standardize Create the rules for maintaining
  and controlling the first 3 Ss. Make it visual
  so all can see the rules and can quickly
  understand.
• Sustain Ensure adherence to the
• 5S standards through communication,
  training, and self- discipline.

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Lean Tools Suite
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The 5 WHYS 8

• WHAT IS 5 WHYS? a problem solving technique
  that allows you too get at the root cause of a
  problem fairly quickly.

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The 5 Whys

• WHY 5 WHYS?
• To often we fix the perceived problem and the
  real, or root cause, is not been addressed
• This is a straightforward means of getting to
  the root cause of the problem.

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The 5 Whys

• Benefits Of The 5 Whys
• It helps to quickly identify the root cause of a
  problem.
• Relationships between different root causes of a
  problems are identified

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The 5 Whys

• When Is 5 Whys Most Useful?
• When problems involve human factors or
  interactions.
• In day-to-day business life.

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The 5 Whys

• How To Complete The 5 Whys
• Formally write down the specific problem.
• Ask WHY the problem happened and write the
  answer below the problem.
• If the answer you just provided doesn't identify
  the root cause of the problem that you wrote down
  in step 1, ask Why again and write that answer
  down.
• Loop back to step 3 until the team is in
  agreement that the problem's root cause is
  identified.

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The 5 Whys PRACTICE

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Lean Tools Suite
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Visual Systems 9(OR VISUAL CONTROL)

• A visual system is a group of visual devices that
  are intentionally designed to share information
  at a glance, without having to say a word. The
  term visual information includes messages
  communicated through any of the senses
• Taste Hearing
• Touch Smell
• Sight

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Visual Systems (OR VISUAL CONTROL)

• Establish what you know about visible system.

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Visual Systems(OR visual control)

• A Visual Workplace is a work environment that
  is self-explaining, self-ordering,
  self-regulating ---- where what is supposed to
  happen does happen, on time, every time

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Visual Systems(OR visual control)

• To become a visual workplace ask these questions
• What do I need to know?
• What do I need to share?
• Once answered one can start to make visual aids

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Visual Systems(OR visual control)

• An excellent place to use visual systems in the
  office is in file drawers, on the outside of file
  drawers and hanging above file drawers.
• Hanging File Folders can be labeled and color
  coded
• Files folders can have return addresses, also
  color coded on them
• Outside of drawers can be labeled with contents
• General file contents can be displayed above the
  files

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Visual Systems(OR visual control)

• Your desk can be made visual
• In basket
• your scissors hang
• stapler in placed and is it labeled so it can
  find its way home
• your three ring binders labeled and filed in a
  visual manner
• your files set up so that a co-worker could find
  the correct file in a
• reasonable time if needed

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Visual Systems(OR visual control)
Have you been saved by this?
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HOMEWORK PRACTICE
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HOMEWORK PRACTICE
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HOMEWORK PRACTICE