Introduction to LEAN

Workshop March 2nd, 2018

Ian Marshall – Lean Champion

Canadian Manufacturers & Exporters

Objectives

Ian Marshall – Canadian Manufacturers & Exporters

‘Introduce the terminology and philosophy of LEAN Thinking’ ‘Demonstrate the benefits of LEAN through simulation’

What is your level knowledge or experience of LEAN/Continuous Improvement: Beginner – limited knowledge Intermediate – some hands-on experience Advanced – number of years of experience

Introduction

Ian Marshall – Canadian Manufacturers & Exporters

Five Principles

of Lean Thinking

Customer Value - The only perception of Value that matters…

is the perception held by the customer

Value Stream - Map the Value Stream – keep it simple & involve

those who work the process… help them to see

Flow - Think flow – make everything flow without interruption…

stoppages collect cost, errors & waste

Pull - Let your Customer ‘Pull’ from you what they need when they need it

Perfection - pursue perfection… not competitors

Jim Womack - Lean Thinking

David Hogg – High Performance Solutions

Map the Value Stream

Process Steps

Cycle Times

Issues

Root Causes

Solutions

“Wherever there is a customer, there is always a value stream… your challenge is to see it.”

Jim Womack - Lean Thinking

Ian Marshall – Canadian Manufacturers & Exporters

Information and Material Flow

Material

Information

Supplier Customer

Ian Marshall – Canadian Manufacturers & Exporters

How Lean Thinkers Think

More than 95% of total lead time

is usually Non-Value Adding time [Of remaining 5% ~ 2.5% is NVA but necessary ~ Hence 2.5 is VA]

Thinking Lean

begins by

focusing on

these spaces

Lead Time

-

Adding Cost

(Opportunity

or waste)

Adding Value

Red: Non-Value Adding time

(waiting, checking, moving, reworking etc.)

Green: Value Adding time

(designing, sourcing, installing, testing etc..)

Quote Cash

David Hogg – High Performance Solutions

The Classic Wastes

*Waste: That which adds cost with no value provided to the customer

For Service

Transport of Documents

Backlog of Work

Unnecessary Motion

Waiting for the Next Step

Doing Work Not Requested

Process Steps & Approvals

Errors in Documents

Not able to share talents…

Developed by Taiichi Ohno

David Hogg – High Performance Solutions

For Manufacturing

Transportation

Inventory

Movement

Waiting

Overproduction

Over Processing

Defects

Skills Underutilization

Product & Process Innovation, Inc.

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

The Toyota Way

Challenge Kaizen Respect Teamwork Go & See

Continuous

Improvement

The Toyota Way 2001

Respect

For

People

Lean Sensei International

The Toyota Way

“Everything we do is for the

purpose of showing us where the

problems are. We must constantly

identify problems, find their causes

and solve them in order to improve

for the long-term.”

David Meier, author of Toyota Culture

Lean Sensei International

Ian Marshall – Canadian Manufacturers & Exporters

Intro to Lean Tools

Video www.cme-mec.ca/mb

Ian Marshall – Canadian Manufacturers & Exporters

https://www.youtube.com/watch?v=OrHxPSyTTMk

The Machine That Changed The World – Womak, Jones & Roos

Lean Thinking – Womak

The Toyota Way – Liker

The High-Velocity Edge – Spear

Everything I Know About Lean I Learned in First Grade – Martichenko

Creating A Lean Culture – Mann

Leading The Lean Enterprise Transformation – Koenigsaeker

The Lean Turnaround – Byrne

Lean Office And Service Simplified - Locher

Managing To Learn – Shook

Understanding A3 Thinking – Sobek & Smalley

2 Second Lean - Akers

People (A leader’s day-to-day guide to building, managing and sustaining lean

organizations) – Gran, Martichenko, Miller & Pearce

Resources - books

Ian Marshall – Canadian Manufacturers & Exporters

www.cme-mec.ca

www.leansensei.com

www.lean.org

www.sme.org

www.ame.org

www.itc.mb.ca

www.TWI-Institute.com

www.superfactory.com

www.productivitypress.com

Resources - websites

David Chao – Lean Sensei International

Ian Marshall – Canadian Manufacturers & Exporters

Ian Marshall – Canadian Manufacturers & Exporters