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Mark Graban
@MarkGraban
www.PracticingLean.com
www.LeanBlog.org
Slides & More:www.MarkGraban.com/LALMS
Reflections on 20+ Years Trying to Get Better at Lean
in Manufacturing & Healthcare
www.louisebatz.org
Practicing Medicine
Practicing Law
Practicing Lean?
© Nicole Yearly (“chicagozen“ on Flickr), used under Creative Commons License
Implementing
Practicing
Learning
LearningBy
Doing
LearningBy
Doing**With a Qualified Coach
“I’m Jim Pell.I’ve been learning Lean for 25 years.”
LearningThroughMistakes
e
We AllMAke
Misteaks
One ofMy
Mistakes(2004)
“My” Kanban System
When inventory reaches 2160, take care to Level 4 Meterbody kanban board.
Qty to build: 660 units
Actual Build Qty:
“My” Kanban System
When inventory reaches 2160, take care to Level 4 Meterbody kanban board.
Qty to build: 660 units
Actual Build Qty:
Or…
eansisguidedlyxecuted
Or…Just not good
at this yet?
Their Kanban System
We All StartSomewhere
eansistakenlyxplained
“Toyota would tell you to kick the patient out of the
room at 19:59 because you have to keep on takt time.”
Dunning-Kruger EffectUnskilled and unaware of it: how difficulties in recognizing one’s own incompetence lead to inflated self-assessments – Kruger & Dunning (1999)
100%
0%None Experience Expert
Con
fiden
ce
We All StartSomewhere
“Which Lean Tool Should I
Start With?”
Start from need.
What problem are we trying to solve?
“Which Lean Tool Should I
Start With?”
“Always start with 5S”
“Always start with 5S?”
We’ve Always Done it
That Way
ToyotaProduction
System
ThinkingProduction
System
Learn, But Don’t Copy
eansisguidedlyxecuted
Right Tool, Wrong Culture
7 am
8 am9 am10 am11 am12 am1 pm2 pm
92
92
92
9292
92
9292
BLOCKS • Plan• Actual• Reasons why
Right Tool, Wrong Culture
Right Tool, Wrong Culture
7 am
8 am9 am10 am11 am12 am1 pm2 pm
92
92
92
9292
92
9292
BLOCKS60
60
60
6045
60
1430
My GM Mistakes• Ergonomic assist• Kanban tooling board• Calling out the manager• Quality or cost?
1996 Current State at GM
• Worst performing engine plant
• Worst performing part of GM Powertrain
• Worst performing part of GM N.A.
• Worst performing part of GM
• Worst performing automaker
"We were offering suggestions and getting pushback on safe
staffing, yet being told to reduce the number of pens and pencils.”
Or…
eansistakenlyxplained
“Go ahead and use Lean on that quality problem…
you’ll speed up your quality problem and make bad stuff faster.”
“Lean will help you to reduce or eliminate [wastes] 1 through 6.
Six Sigma will help you to reduce number 7 [defects].”
Jidoka Just-in-Time
“If lots of people are upset, it’s not really TPS.”
ComplainingAbout
Resistance
Complaining About Lack ofSustainment
“We were only holding the gains on about
40 percent of those
[Kaizen Events]”
Lack ofAdoption?
“We’ve been implementing Lean
for 5 years… now we’re focusing on
continuous improvement.”
WhyLean?
WhyLean?
90%??
Why BeBetter at
Lean?
• Don’t be afraid to make mistakes
• Learn from the mistakes of others
• Try to anticipate possible mistakes
• Make small mistakes to prevent big mistakes
• Don’t keep making the same mistakes
If You’re New to Lean…
• Share your early mistakes
• Call out “Fake Lean?”
• Be patient & respectful
• Always be a learner, and be making new mistakes
If You’re Experienced…
• Make sure you’re staying true to Lean without being too dogmatic
• Think about how people might misunderstand what you’re teaching
• Discuss pro-active countermeasures to L.A.M.E. or “Fake Lean”
If You’re Teaching…
Learn bydoing
Do it right the first time
Q&A / Contact Info• www.MarkGraban.com • www.LeanBlog.org• [email protected] • Slides & More:
www.MarkGraban.com/LALMS
www.PracticingLean.com
