21st Annual APMP® International Conference & Exhibits
Using Lean Principles Using Lean Principles to Eliminate Proposal to Eliminate Proposal
WasteWaste
June 3, 2010June 3, 2010Roger CampbellRoger Campbell
Pratt & Whitney RocketdynePratt & Whitney Rocketdyne
21st Annual APMP® International Conference & Exhibits
Outline
• How can you Benefit?• What are Lean Principles?• Applying Lean Principles to proposals
– Reviews – single piece flow– Do/Don’t Use – defect elimination– Top down – eliminating overproduction waste
• Recap
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21st Annual APMP® International Conference & Exhibits
How can you Benefit?
• Lean principles can help you create proposals more efficiently– Reducing Bid and Proposal costs– Enhancing team communication and
commitment
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21st Annual APMP® International Conference & Exhibits
What are Lean Principles?
• Toyota origin– Specify value– Identify value stream– Make flow visible– Let customer pull– Eliminate waste
• Not just tools (e.g., 5S)
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Focus on Lean Principles, not just Lean tools
ToyotaProduction System
LevelingKaizen (Continuous Improvement),
Standard Work (5S)
Just-In-TimeRight part,Right amount, Right time,Flow,Pull
Jidoka(Built in Quality)Stop the line,Intelligent Automation
21st Annual APMP® International Conference & Exhibits
Value & Value Streams
• As measured by the customer• Make to use• Actions to take product from material to delivery
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Understanding customers key to determining Value
21st Annual APMP® International Conference & Exhibits
First Floor
Flow & Customer Pull
• Single-piece flow vs. batch processing
• Focus on the product and its needs
• Produce the product in response to a customer order
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Flow eliminates inventory, raises productivity
PipeCutting
Fin-Press
Expansion
CleanLeakTest
Braze
PartsStorage
Final Assy.
Test, Pack,Ship
Showa Coil Making, After
Second Floor
First Floor
Showa Coil Making, Before
Finished CoilStorage
Finished CoilStorage
Finished UnitStore &
ShipFinal Test
Final Assy. Track
PipeCutting
SFin-
Press
S Expansion
S Clean SLeakTest
S Braze S
Intermediate Storage Conveyor
21st Annual APMP® International Conference & Exhibits
Waste Elimination
• Eliminate non-value added tasks
• Don’t make, pass or accept defects
• Seven wastes
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Efficiency driven by waste/defect elimination at origin
21st Annual APMP® International Conference & Exhibits
Applying Lean Principles
• “Sure, this stuff applies in a factory environment, but I do proposals…”
• Do proposals…– Have customers?– Use processes?– Have products?– Produce waste?
Proposal processes/practices ripe for Lean use
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21st Annual APMP® International Conference & Exhibits
Proposal (Pink/Red) Reviews
• Batch processing– Fastest writer waits– Lost time for read
ahead and production
• Still valuable– Horizontal integration– Checkpoint– Independent view
Traditional review process wasteful
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21st Annual APMP® International Conference & Exhibits
Lean Proposal Reviews
• Single piece flow– Writer requests (pulls) review
when ready– Rolling review by Proposal Mgr– Pink/Red team members
engaged (no read ahead)
• Don’t integrate– No lost time for production
Collocated Implementation
- Ready for review
- Proposal Mgr approval to engage Pink/Red team members - See comments, on target - See Proposal Mgr, off target
Lean reviews minimize writer downtime
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21st Annual APMP® International Conference & Exhibits
Kickoff Meeting Baselines
• What are we proposing?– Program Plan
• What is the win strategy?– Executive Summary
• What is expected of me?– Schedule– Detailed outline
Clear baselines eliminate defects and rework
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21st Annual APMP® International Conference & Exhibits
Another Useful Baseline
• Do/Don’t Use list combines– Fact Dictionary– Glossary– “Hollow” terms
Do Use:“We have invested $6.5M incompany funds to develop…”Lean – A set of integratedprinciples/tools focusing…”
Don’t Use:UniqueBest-in-ClassWorld Class“…55 years as the …”
Most efficient to prevent defects from occurring
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21st Annual APMP® International Conference & Exhibits
Bottom’s Up = Overproduction
• Rough outline only• Poor page count
discipline• Weak/no storyboards• Quality “inspected in”• Many rewrites• “Cut to fit”
Words/graphics not used are costly
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21st Annual APMP® International Conference & Exhibits
Top Down = Minimizes Waste
• Executive Summary• Detailed outline with
margin• Margin reduced
after each review
Avoid “cut to fit”, compliance may suffer
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95
96
97
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99
100
101
1/0
1/5
1/1
0
1/1
5
1/2
0
1/2
5
1/3
0
2/4
Date
Pa
ge
co
un
t S
tatu
s
Target
Actual
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21st Annual APMP® International Conference & Exhibits
Top Down = Minimizes Waste (2)
Daily Page Count Stoplight Chart
Section Alloc. 3/29 3/30 3/31 4/1 4/2
2.1 5 4.5 5 5 5 4.5
2.2 5 6 5.5 5 5 5
2.3 2 3 2 2 2 2
2.4 7 8 7 7 7 7
2.5 6 8 8 6.5 6.5 6
• Strong focus on storyboards
• Daily attention to page count status
Only create the words/graphics that will be used
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21st Annual APMP® International Conference & Exhibits
Recap
• Four Lean proposal examples were described, providing– Reduced Bid and Proposal costs– Enhanced team communication and
commitment
• Further reading:– Lean Thinking, Womack & Jones– The Toyota Way, Liker
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