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Lean Project Management
PrinciplesWhat is lean?
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Origins of Lean
The Toyota Production System
by Taiichi Ohno
Various titles by Shigeo Shingo
The Machine that Changed the Worldby Womack and Jones
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Principles of Lean
• Identify value• Map the Value Stream• Create Flow• Establish Pull• Seek Perfection
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Seven Sources of Waste
• The process• Methods• Movement• Product defects• Waiting time• Over-production• Inventory
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Examples of these wastes in your office
• The process• Methods• Movement• Product defects• Waiting time• Over-production• Inventory
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Characteristics of Lean Environments
• Flow manufacturing• Process flexibility• Total quality management• Total productive maintenance
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Characteristics of Lean Environments
• Uninterrupted flow• Continuous process improvement• Supplier partnerships• Total employee involvement
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Importance of Lean
Lean is not primarily an inventory reduction program. Its primary purpose is to focus attention on problems.
Deming on Lean
The great advantage of the [Lean] system is the discipline behind it - processes in control; quality, quantity, and regularity predictable.
Out of the Crisis
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5S’s
• Sort:Organization (Seiri)• Set in order: Orderliness (Seiton)• Shine: Cleanliness (Shitsuke)• Standardized Cleanup (Seiso)• Sustain: Discipline (Seiketsu)
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Five S
• Sort
• Set in Order
• Shine
• Standardize
• Sustain
REDTAG
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Set in Order
• A place for everything and everything in its place.
• Tool cutouts
• Taped outline on floor or bench
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Set in Order
• A place for everything and everything in its place.
• Tool cutouts
• Taped outline on floor or bench
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Shine
• Keep everything clean and swept
• System maintenance and inspection
• Problems (e.g., oil leaks) are more easily spotted when the workplace is in order
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Standardize
• Standardize ensures that your progress in 3S implementation is not wasted.
• Procedures, schedules, practices
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Sustain
• Deming’s point number 1: Constancy of purpose
• The leadership of supply is responsible for sustaining the process.
• MBWA
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Sources of Service Wastes
• The process• Methods• Movement• Product defects• Waiting time• Over-production• Inventory
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Advantages of Setup Reduction
• Reduced EOQ
• Reduced queue & mfg. Lead time
• Reduced WIP
• Improved quality
• Improved process and material flow
How does these related to product development / PM?
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Reference
• Decoding the DNA of the Toyota Production System, Steven J. Spear, Kent Bowen, Harvard Business Review, September, 1999.
