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Large Scale Program Transformation using Lean

Practical Insights in Implementing Lean Principles

By

Krishnamurty VG Pammi

Agile Coach

IVY Comptech

Case In point

Note: This case in point does not belong to / represent IVY Comptech in anyways. I am taking this case in point from my experience just to express my view point that how Lean principles can be effective

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Program - Before Lean Implementation

Unhappy Customers

Process not meeting the targeted Productivity

Demotivated Employees

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Scope- A Test Maintenance program where the primary objective is to identify new regression breaks in various Test releases (Breadth and Depth Test Passes) that do not exist in previous, released versions of Windows

Revenue : 4 million USD

Peak Team Size = 120 members

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Lean Model that worked for us…. Goal – “Sustainable shortest lead time, best quality and value”

Learn to see the “whole”

Continuous Improvement

Challenge Everything till convinced Go-See with Your Feet , 5 Whys

Respect For the People (On the assembly line the person at the next workstation is also our customer)

Lean Principles

Transformation Model

Lean Principles Implemented

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SL # Lean Principle

1 Value Stream Mapping

2 Takt Time

3 Work Load Levelling

4 SMED

5 5S

6 Visual Control

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Takt Time : Scenarios/ Person Day

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Suite Apps

AV/Utility Apps

Game Applications

TRADITIONAL TEST EXECUTION

TAKT

TIME

2500 Scenarios

Customer wants to test 2000 Unique Apps with 2500 Scenarios at the end of 2

weeks with

Available time: 2 weeks

Demand: 2500 Scenarios

Takt time: 250 Scenarios/Day

Let us optimally utilize resources in such a way that we produce only 250

scenarios a day. If we follow traditional approach, we will end up extending

the schedule. In the traditional approach, we used to go with 3 app scenario/tester day productivity norm. Thus, used to take more time.

DAYWISE COMPLETED SCENARIOS

250 Scenarios

250 Scenarios

250 Scenarios

250 Scenarios

250 Scenarios

CONFIDENTIAL© Copyright 2005 Wipro Ltd 8

In traditional approach – Productivity

norm of 3 scenarios/person day formed the

basis to calculate our duration. We used to

take 15 to 20 days to complete this TP.

Work Load Leveling

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Distribute the Apps equally for 2 Weeks (10days) in such a way that every day all category & complexity Apps are covered

Suite Apps Utility/AV Apps Games

High Medium Low High Medium Low High Medium Low Total

Day1 53 22 28 36 21 17 8 27 38 250

Day2 38 27 8 17 21 36 28 22 53 250

Day3 17 21 36 53 28 22 38 8 27 250

…

Day10 XX YY ZZ AA AS AX BX BY BZ 250


Application

Complexity

Analysis

Resource Profiling

Work Allocation

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Lean Tenant: SMED (Single Minute Exchange of Die)

ID Task

1 OS installation

1.1 Base OS

1.2 Windows Update

1.3 System Drivers

1.4 IE Proxy Setting

1.5 Media Search

2 Install Package Pre requisite for GDR

2.1 Install Offline packages for GDR

3 Install SP builds

4 Medusa Setup

5 MTC Setup

6 Install Application

7 Upgrade Scenarios

ON OFF Displace • System Drivers

•IE Proxy

•Media Search

•Install Package Pre Requisite

•Install offline packages for GDR

•Medusa Setup

•MTC Setup

Reduce

• Media search time got reduced

Standardize

• Formed Setup and Media Team

25%

25%

Setup Reduced to 15 hour from 65 hours (Net Gain of 50 hours per day)

50%


Lean Tenet : 5S

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Utilized 5S to fasten the media search and media availability through out the Test Pass.


Lean Tenet: Visual Controls

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262% improvement in productivity

Setup Reduced to 15 hour from 65 hours (Net Gain of 50 hours per day)

Effective Hardware Utilization

We have bandwidth to take new features testing

Happy Employees.

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Program – After Lean Implementation

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By

Krishnamurty VG Pammi

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