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LEAN Thinking!
Ian Marshall – LEAN ChampionCanadian Manufacturers & Exporters
www.cme-mec.ca/mb
Ian Marshall – Canadian Manufacturers & Exporters
Why go LEAN?
Five Principlesof LEAN Thinking
Ian Marshall – Canadian Manufacturers & Exporters
Five Principlesof LEAN Thinking
1. The only perception of Value that matters… is the perception held by the customer
2. Map the Value Stream – keep it simple & involve those who work the process… help them to see
3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste
4. Let your Customer ‘Pull’ from you what they need when they need it
5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking
Ian Marshall – Canadian Manufacturers & Exporters
Five Principlesof LEAN Thinking
1. The only perception of Value that matters… is the perception held by the customer
2. Map the Value Stream – keep it simple & involve those who work the process… help them to see
3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste
4. Let your Customer ‘Pull’ from you what they need when they need it
5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking
Ian Marshall – Canadian Manufacturers & Exporters
Map the Value Stream
Process Steps
Cycle Times
IssuesRoot CausesSolutions
Ian Marshall – Canadian Manufacturers & Exporters
“ “Wherever there is a customer, there is always a value stream… Wherever there is a customer, there is always a value stream… your challenge is to see it.”your challenge is to see it.”
Jim Womack - Lean ThinkingJim Womack - Lean Thinking
Five Principlesof LEAN Thinking
1. The only perception of Value that matters… is the perception held by the customer
2. Map the Value Stream – keep it simple & involve those who work the process… help them to see
3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste
4. Let your Customer ‘Pull’ from you what they need when they need it
5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking
Ian Marshall – Canadian Manufacturers & Exporters
Ian Marshall – Canadian Manufacturers & Exporters
Think of rocks and boulders as “waste” because they slow down the water flow. Lean is focused on eliminating these barriers so that water (or production) can flow smoothly without interruptions.
Lean = flow
Ian Marshall – Canadian Manufacturers & Exporters
SalesEngineering
PlanningPurchasing
Production
Information and Material Flow
PartsAssembly Paint
Finishing Shipping
Cash
Quote
Information and Material Flow
Ian Marshall – Canadian Manufacturers & Exporters
What percentage of lead time is Waste?
The Seven Wastes
*Waste: That which adds cost with no value provided to the customer
For ServiceFor Service Errors in DocumentsErrors in Documents Transport of DocumentsTransport of Documents Doing Work Not RequestedDoing Work Not Requested Waiting for the Next StepWaiting for the Next Step Process Steps & ApprovalsProcess Steps & Approvals Unnecessary MotionUnnecessary Motion Backlog of WorkBacklog of Work
Developed by Taiichi Ohno - classic Toyota Seven Wastes
For For ManufacturingManufacturing
DefectsDefects TransportatioTransportatio
nn OverproductioOverproductio
nn WaitingWaiting ProcessingProcessing MovementMovement InventoryInventory
Product & Process Innovation, Inc.
Ian Marshall – Canadian Manufacturers & Exporters
Ian Marshall – Canadian Manufacturers & Exporters
Obtain docs Prep docs Queue
4 8 12 16 20 24 28 32 36
Selection Com.Assess Letter Sign agrmt.Certificate
Obtain docs Prep docs Buffer
4 8 12 16 20 24
Sign agrmt.
4 8 12
Current State
6 Months Future State
Long-Term Future State
40% reduction of cycle time
50% reduction of cycle time
Screen Visit
Screen VisitAssess
&Letter
Certificate
ScreenVisit
+assess
LetterObtain docs
Lead Time Reduction
Five Principlesof LEAN Thinking
1. The only perception of Value that matters… is the perception held by the customer
2. Map the Value Stream – keep it simple & involve those who work the process… help them to see
3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste
4. Let your Customer ‘Pull’ from you what they need when they need it
5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking
Ian Marshall – Canadian Manufacturers & Exporters
Service at the touch of a button!
Ian Marshall – Canadian Manufacturers & Exporters
Materials on site when you need them!
Ian Marshall – Canadian Manufacturers & Exporters
Five Principlesof LEAN Thinking
1. The only perception of Value that matters… is the perception held by the customer
2. Map the Value Stream – keep it simple & involve those who work the process… help them to see
3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste
4. Let your Customer ‘Pull’ from you what they need when they need it
5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking
Ian Marshall – Canadian Manufacturers & Exporters
Lean Sensei International
The Toyota Way
Challenge Kaizen Respect Teamwork Go & See
ContinuousImprovement
The Toyota Way 2001
RespectFor
People
LEAN Definition
“LEAN is an Operations’ Strategy with a new set of Values to Engage People in Continuously Improving Safety, Morale, Quality, Cost and
Productivity.”
Jeffrey Liker, author of The Toyota Way
Lean Sensei International
Toyota Philosophy…
Average person +
Standardized work environment+
Challenge=
Performance Excellence…
Ian Marshall – Canadian Manufacturers & Exporters
Ian Marshall – Canadian Manufacturers & Exporters
Ian Marshall – Canadian Manufacturers & Exporters
Ian Marshall – Canadian Manufacturers & Exporters
Resources
Ian Marshall – Canadian Manufacturers & Exporters
www.cme-mec.cawww.lean2015.com www.leansensei.comwww.lean.org www.sme.orgwww.ame.orgwww.TWI-Institute.comwww.superfactory.com www.productivitypress.com
Resources - websites
David Chao – Lean Sensei International
Ian Marshall – Canadian Manufacturers & Exporters
Resources - booksThe Machine that Changed the World –
Womack, Jones & Roos
Lean Thinking – Womack & Jones
The Toyota Way – Liker
Toyota Culture – Liker & Hoseus
The Toyota Way to Lean Leadership – Liker & Convis
Toyota Kata - Rother
The High Velocity Edge – Spear
Managing to Learn – Shook
Understanding A3 Thinking – Sobek & Smalley
Leading the Lean Enterprise Transformation – Koenigsaeker
David Meier, Jeffrey Liker, Michael Hoseus
Ian Marshall – Canadian Manufacturers & Exporters