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Lean Inventive Systems ThinkingPractitioner’s Work Book
Crafitti ConsultingCrafting Innovation Together
Crafitti Innovation Ignition Workshop SeriesSep 26-27, 2008, Bangalore, India
Delegate Name:
Organization:
Email-Id:
© Crafitti Consulting Private Ltd.
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Defining the Problem
(EC3 Framework)Expand,
Collect, ConnectConverge
2© Crafitti Consulting Private Ltd.
Inventive Thinking
?
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Expand
3© Crafitti Consulting Private Ltd.
SUPER-
SYSTEM
SYSTEM
SUB-SYSTEM
PAST PRESENT FUTURE
Nine Windows (or the System Operator Tool) helps you sketch or place your problem in a broader space time context. Solutions to problems are often found in the areas adjoining the system in question.
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User Needs
4© Crafitti Consulting Private Ltd.
The Six Senses
Sight
Sound
Smell
Taste
Touch
Linguistic
Musical
Logical
Spatial
Kinesthetic
Inter-personal
Intra-personal
Time Purchase Delivery Use Supplements Maintenance Disposal
Space Home Work Fun On-the moveAt high
altitudesOutside
India
Quality Usability AestheticsProductivity
Reliability Efficiency Adaptability
Needs are perceptional in nature, governed by the five senses (and the sixth sense – intelligence).
The needs map gives a quick overview of the how the six senses are gratified by the product at the product-user interfaces – space, time and quality
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System Dependency Matrix
Element 1 Element 2 Element 3 Element 4
Element 1 ×
Element 2
Element 3 ×
Element 4 ×
5© Crafitti Consulting Private Ltd.
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The System Function Map
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Sore Point
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Contradictions
7© Crafitti Consulting Private Ltd.
Improving factors
Worsening factors
Weight of moving object Stress or pressure Power Object-generated harmful factors
Weight of stationary object Shape Loss of Energy Ease of manufacture
Length of moving object Stability of the object's composition Loss of substance Ease of operation
Length of stationary object Strength Loss of Information Ease of repair
Area of moving object Duration of action of moving object Loss of Time Adaptability or versatility
Area of stationary object Duration of action by stationary object Quantity of substance/the matter Device complexity
Volume of moving object Temperature Reliability Difficulty of detecting and measuring
Volume of stationary object Illumination intensity Measurement accuracy Extent of automation
Speed Use of energy by moving object Manufacturing precision Productivity
Force (Intensity) Use of energy by stationary object Object-affected harmful factors
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Laws of Evolution
8© Crafitti Consulting Private Ltd.
0
1
2
3
4
Increasing Ideality
Increasing Dynamism
Increasing Multiplication
Transition from Macro to Micro
Increasing SynchronizationTransition to Higher Level System
Non-uniform evolution of sub-systems
Decreasing human element
Shortening of Energy Flow Path
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Ideal Final Result
Now
Point of End of Feasibility
What would be the ideal final result?
9© Crafitti Consulting Private Ltd.
Ideality Quotient = Benefits(Cost + Harmful Effects)
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Collect
10© Crafitti Consulting Private Ltd.
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Connect
TP 1 TP 2 TP 3 TP 4 TP 5 BP 1 BP 2 BP 3 BP 4 BP 5
TP 1 1
TP 2 1
TP 3 1
TP 4 1
TP 5 1
BP 1 1
BP 2 1
BP 3 1
BP 4 1
BP 5 1
11© Crafitti Consulting Private Ltd.
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Converge
Problems Contradictions
Technical
1.
2.
3.
1.
2.
3.
Business
1.
2.
3.
1.
2.
3.
12© Crafitti Consulting Private Ltd.
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Searching for novel solutions
13© Crafitti Consulting Private Ltd.
Inventive Thinking
!
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Inventive Principles - TRIZ
1. Segmentation
2. Taking Out
3. Local Quality
4. Asymmetry
5. Merging
6. Universality
7. Nested Doll
8. Anti-weight
9. Preliminary anti-action
10. Beforehand Cushioning
11. Equipotentiality
12. The other way round
13. Spheroidality
14. Dynamics
15. Partial or Excessive Actions
16. Another dimension
17. Mechanical Vibration
18. Periodic Action
19. Continuity of useful action
14© Crafitti Consulting Private Ltd.
20. Skipping21. Blessing in disguise22. Feedback23. Intermediary24. Self-service25. Copying26. Cheap short-living
objects27. Mechanics
substitution28. Pneumatics and
hydraulics29. Flexible shells and
thin films30. Porous materials31. Colour changes32. Homogeneity33. Discarding and
recovering34. Parameter changes35. Phase transitions36. Thermal Expansion37. Strong Oxidants38. Inert atmosphere39. Composite Materials
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Ideal Final Result
Now
Ideas beyond the point of feasibility
The ideal final result?
15© Crafitti Consulting Private Ltd.
Ideality Quotient = Benefits(Cost + Harmful Effects)
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Vedic Inventive Principles
16© Crafitti Consulting Private Ltd.
1. Observation
– Pure observation
– Flag
2. Comparison
– Suitability
– Proportion
3. Addition
– One more than before
– Sum of properties
– Sum of qualities
– Qualities of the sum
– Encapsulation
4. Subtraction
– One less than before
5. Variation
– What’s less?
– What’s more?
– Cause Movement
6. Rotation
– Reverse or exchange
– Multiple angles
– Destroy and rebuild
7. Division
– Complete and incomplete
– Part and Whole
– Individual and collective
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Laws of Evolution
17© Crafitti Consulting Private Ltd.
0
1
2
3
4
Increasing Ideality
Increasing Dynamism
Increasing Multiplication
Transition from Macro to Micro
Increasing SynchronizationTransition to Higher Level System
Non-uniform evolution of sub-systems
Decreasing human element
Shortening of Energy Flow Path
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The System Function Map
18© Crafitti Consulting Private Ltd.
Sore Point
1. Trimming– Eliminate harmful interaction
– Eliminate incomplete interaction
– Eliminate a field
– Eliminate a substance
2. Add – New substance
– New Field
3. Modify
– Substance
– Field
– Incomplete interaction
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The Solutions Mind-Map
19© Crafitti Consulting Private Ltd.
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Putting it all together
20© Crafitti Consulting Private Ltd.
Systems Thinking
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Connect
I1 I2 I3 I4 I5 I6 I7 I8 I9 I10
I1 1
I2 1
I3 1
I4 1
I5 1
I6 1
I7 1
I8 1
I9 1
I10 1
21© Crafitti Consulting Private Ltd.
I: Idea
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Converge - Impact
22© Crafitti Consulting Private Ltd.
S1 S2 S3 S4 S5 S6
TP 1
TP 2
TP 3
BP 1
BP 2
BP 3
Clusters of ideas form solutions (S) for Technical Problems (TP) and Business Problems (BP)
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Converge
Problems Solutions
Criteria
Technical
1.
2.
3.
1.
2.
3.
Business
1.
2.
3.
1.
2.
3.
23© Crafitti Consulting Private Ltd.
Identify criteria against which solutions can be evaluated and prioritized
objectively
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Converge - Relative Prioritization
24© Crafitti Consulting Private Ltd.
Criteria Solutions
Criteria1
Solutions
Criteria2
Solutions
Criteria 3
Solution Priority
The Analytic Hierarchy Process is suitable to be used in multi-criteria decision making scenarios where relative prioritization based on expert judgment is required (due to lack of suitable or relevant absolute measures)
Holistic Goal
Rank Order
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Into Production
25© Crafitti Consulting Private Ltd.
LeanThinking
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The Value Stream Map
26© Crafitti Consulting Private Ltd.
What is the “value” that is being delivered to the customer?
What are the activities that are being done to generate this value?
For each activity note down theCycle Time:Value-added Time:How many resources are consumed?
What is the error rate?
What is the overall “rate of demand”?
What is the average service rate?
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Making it Flow
27© Crafitti Consulting Private Ltd.
Identify in the VSM:1. Wait times/ delays2. Idle Time3. Changeover time4. Overload5. Variable workload/
work rate6. Excess travel7. Excess transport8. Rework9. Variation from
expectation (better or worse)
10. Over-processing (unnecessary work)
11. Resource crunch12. Clutter13. Communication
delay14. Cacophony
•Make changes to the VSM to eliminate the identified problems•Create small change experiments to validate
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Enabling Pull Mode
28© Crafitti Consulting Private Ltd.
Identify in the VSM:1. The Takt time (rate
of demand)2. The service rate
(rate of supply)3. Minimum batch size
Make changes to the VSM:1. Synchronize with
Takt time2. Work with smallest
possible batch size3. Mechanisms for
demand changes to quickly register across the system
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Building quality in
• What are the overall quality goals?
• How do they map to specific goals for sub-activities?
• How to ensure that these goals are met without spending extra time on review?
Incorporate identified measures into the activities
29© Crafitti Consulting Private Ltd.
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How much did we improve?
Flow
Pull
Built-in quality
Improved Process
Initial Process
Value Stream
30© Crafitti Consulting Private Ltd.
•Service Rate•Cycle Time•Resources used•Error rate
•Service Rate•Cycle Time•Resources used•Error rate
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Takeaways for product innovation life cycle
Inventive Thinking
31© Crafitti Consulting Private Ltd.
Systems Thinking
Lean Thinking
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Lean Inventive Systems Thinking
Crafitti ConsultingCrafting innovation together . . .
www.crafitti.com
Navneet Bhushan ([email protected])
Karthikeyan Iyer ([email protected])
32© Crafitti Consulting Private Ltd.
Crafitti Innovation Ignition Workshop SeriesSep 26-27, 2008, Bangalore, India