LEAN Thinking!

Ian Marshall – LEAN ChampionCanadian Manufacturers & Exporters

www.cme-mec.ca/mb

Ian Marshall – Canadian Manufacturers & Exporters

Why go LEAN?

Five Principlesof LEAN Thinking

Ian Marshall – Canadian Manufacturers & Exporters

Five Principlesof LEAN Thinking

1. The only perception of Value that matters… is the perception held by the customer

2. Map the Value Stream – keep it simple & involve those who work the process… help them to see

3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste

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

5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking

Ian Marshall – Canadian Manufacturers & Exporters

Five Principlesof LEAN Thinking

1. The only perception of Value that matters… is the perception held by the customer

2. Map the Value Stream – keep it simple & involve those who work the process… help them to see

3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste

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

5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking

Ian Marshall – Canadian Manufacturers & Exporters

Map the Value Stream

Process Steps

Cycle Times

IssuesRoot CausesSolutions

Ian Marshall – Canadian Manufacturers & Exporters

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

Jim Womack - Lean ThinkingJim Womack - Lean Thinking

Five Principlesof LEAN Thinking

1. The only perception of Value that matters… is the perception held by the customer

2. Map the Value Stream – keep it simple & involve those who work the process… help them to see

3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste

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

5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking

Ian Marshall – Canadian Manufacturers & Exporters

Ian Marshall – Canadian Manufacturers & Exporters

Think of rocks and boulders as “waste” because they slow down the water flow. Lean is focused on eliminating these barriers so that water (or production) can flow smoothly without interruptions.

Lean = flow

Ian Marshall – Canadian Manufacturers & Exporters

SalesEngineering

PlanningPurchasing

Production

Information and Material Flow

PartsAssembly Paint

Finishing Shipping

Cash

Quote

Information and Material Flow

Ian Marshall – Canadian Manufacturers & Exporters

What percentage of lead time is Waste?

The Seven Wastes

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

For ServiceFor Service Errors in DocumentsErrors in Documents Transport of DocumentsTransport of Documents Doing Work Not RequestedDoing Work Not Requested Waiting for the Next StepWaiting for the Next Step Process Steps & ApprovalsProcess Steps & Approvals Unnecessary MotionUnnecessary Motion Backlog of WorkBacklog of Work

Developed by Taiichi Ohno - classic Toyota Seven Wastes

For For ManufacturingManufacturing

DefectsDefects TransportatioTransportatio

nn OverproductioOverproductio

nn WaitingWaiting ProcessingProcessing MovementMovement InventoryInventory

Product & Process Innovation, Inc.

Ian Marshall – Canadian Manufacturers & Exporters

Ian Marshall – Canadian Manufacturers & Exporters

Obtain docs Prep docs Queue

4 8 12 16 20 24 28 32 36

Selection Com.Assess Letter Sign agrmt.Certificate

Obtain docs Prep docs Buffer

4 8 12 16 20 24

Sign agrmt.

4 8 12

Current State

6 Months Future State

Long-Term Future State

40% reduction of cycle time

50% reduction of cycle time

Screen Visit

Screen VisitAssess

&Letter

Certificate

ScreenVisit

+assess

LetterObtain docs

Lead Time Reduction

Five Principlesof LEAN Thinking

1. The only perception of Value that matters… is the perception held by the customer

2. Map the Value Stream – keep it simple & involve those who work the process… help them to see

3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste

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

5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking

Ian Marshall – Canadian Manufacturers & Exporters

Service at the touch of a button!

Ian Marshall – Canadian Manufacturers & Exporters

Materials on site when you need them!

Ian Marshall – Canadian Manufacturers & Exporters

Five Principlesof LEAN Thinking

1. The only perception of Value that matters… is the perception held by the customer

2. Map the Value Stream – keep it simple & involve those who work the process… help them to see

3. Think flow – make everything flow without interruption… stoppages collect cost, errors & waste

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

5. Perfection - pursue perfection… not competitorsJim Womack - Lean ThinkingJim Womack - Lean Thinking

Ian Marshall – Canadian Manufacturers & Exporters

Lean Sensei International

The Toyota Way

Challenge Kaizen Respect Teamwork Go & See

ContinuousImprovement

The Toyota Way 2001

RespectFor

People

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

Toyota Philosophy…

Average person +

Standardized work environment+

Challenge=

Performance Excellence…

Ian Marshall – Canadian Manufacturers & Exporters

Ian Marshall – Canadian Manufacturers & Exporters

Ian Marshall – Canadian Manufacturers & Exporters

Ian Marshall – Canadian Manufacturers & Exporters

Resources

Ian Marshall – Canadian Manufacturers & Exporters

www.cme-mec.cawww.lean2015.com www.leansensei.comwww.lean.org www.sme.orgwww.ame.orgwww.TWI-Institute.comwww.superfactory.com www.productivitypress.com

Resources - websites

David Chao – Lean Sensei International

Ian Marshall – Canadian Manufacturers & Exporters

Resources - booksThe Machine that Changed the World –

Womack, Jones & Roos

Lean Thinking – Womack & Jones

The Toyota Way – Liker

Toyota Culture – Liker & Hoseus

The Toyota Way to Lean Leadership – Liker & Convis

Toyota Kata - Rother

The High Velocity Edge – Spear

Managing to Learn – Shook

Understanding A3 Thinking – Sobek & Smalley

Leading the Lean Enterprise Transformation – Koenigsaeker

David Meier, Jeffrey Liker, Michael Hoseus

Ian Marshall – Canadian Manufacturers & Exporters