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Practical Implementation of Lean Practices to Improve Small / Medium Sized Businesses’ Productivity
Nick Brownsword 21st May 2020
Agenda• Definition of Lean• Two slides of theory!• Practical examples of what lean practices look like
© Productivity People Ltd 2019
Definition - Lean is not:• A cost cutting programme• A programme to reduce headcount• A project we are working on this year• Only applicable to manufacturing operations• Something that is delegated to the shop floor• A programme run by external consultants• A soft approach with intangible outcomes
© Productivity People Ltd 2019
Definition - Lean is:• An approach to eliminating all forms of waste within
a business• A philosophy or a way of thinking• A journey that doesn’t end• Led from the top of the organisation• Engages everyone across a business• Develops the skills and capabilities of the team• Creates a work environment where individuals are
willing to give their discretionary effort• Delivers improved business performance
© Productivity People Ltd 2019
Waste caused by defects or
rejects
Waste caused by unnecessary
movement
Waste caused by inappropriate
processing
Waste caused by waiting
Waste caused by transport
Waste caused by overproduction
Waste caused by unnecessary
stock
Kaizen
Source: Competitive Capabilities International (CCI) TRACC
Best Practices
Leading Change
Teamwork 5S Visual Workplace
Standard Work
Proc
ess/
Mat
eria
l Flo
w
Plan
ning
Proc
urem
ent
Tran
spor
tatio
n
Health and Safety
WORLD’S BEST
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Problem Solving
TPM
/ As
set C
are
Chan
ge o
ver t
ime
redu
ctio
n
War
ehou
sing
Busin
ess P
roce
sses
Practice – Performance Model
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Best Practice – What Does Good Look Like
LEADING AND MANAGING CHANGE
Vision
Daily Activities
Strategy Deployment – connecting teams to the Vision
Best
Pra
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Leading and Managing Change – Best PracticeBe
st P
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Exam
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A3 Business Plan
10
Best
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Best Practice – What Does Good Look Like
HEALTH AND SAFETY
Health and Safety
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Best Practice – What Does Good Look Like
5S – WORKPLACE ORGANISATION
5S
“Our factory is the best selling tool we have” – Marketing Manager
Best
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© Productivity People Ltd 2019
Best
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VISUAL MANGEMENT
Visual Management – Best PracticeBe
st P
ract
ice
Exam
ple
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Visual Management – Best PracticeBe
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Visual Management & ProductivityAre we in
spec?Are we in
spec?
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Manual Planning and Real Time Tracking
• Daily targets by product• Tracked four times each day on the production line
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Team Daily Plan
Operator 1 Operator 2 Operator 3 Operator 48.00 - 8.308.30 - 9.009.00 - 9.309.30 - 10.0010.00 - 10.3010.30 - 11.0011.00-11.3011.30-12.0012.00 - 12.3012.30 - 1.001,00 - 1.301.30 - 2.002.00 - 2.302.30 - 3.003.00 - 3.303,30 - 4.004.00 - 4.30
Best
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PROBLEM SOLVING
Problem Solving – Best Practice
Time
Perf
orm
ance
Daily incremental problem solving: DMS
Breakthrough problem solving: Rapid Improvement Events
Best
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Define – Measure – Analyse – Improve - ControlBe
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Exam
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Best Practice – What Does Good Look Like
TEAM WORK
Teamwork
• Key elements of formal Teamwork to support a lean implementation:• Defined team structure• Defined responsibilities• Shared team objectives• Trained team in lean concepts• Team focus on lean improvements
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Team Work - Skills MatrixBe
st P
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Exam
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STANDARD WORK
Standard Work – Examples Be
st P
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Exam
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Use of SOP’s in the work placefor all key processes
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Use of One Point Lessons for training staff in key issues
Good practice – Leader Standard Work
35
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Summary• The foundational lean practices are applicable to all businesses• It requires leadership from the top and a commitment to stick with it• If you are able to achieve this, you will gain the following benefits:
• Engaged and committed team• Stability of your operations• More time to focus on pro-active improvements• Improved business performance
© Productivity People Ltd 2019
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