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Lean Awareness Training

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Katie Jo Jo

on 13 April 2016

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Transcript of Lean Awareness Training

Objectives
Introductions
Who are you?

What is your role?

What is your experience & understanding of Lean?
What best describes your current role?
Lean overview: What is Lean?
Lean is an approach which seeks to deliver what the customer wants, when they want it, at maximum value with minimum waste.
Lean is a way of thinking (Philosophy)
Lean is a way of doing more with less - less time and less space
At the heart of Lean is flexible, motivates team members
Lean Simulation - Round 1
Building a Lego Gantry Leg
Demonstrate the effects of applying some lean tools to a "real" scenario by showing:

The impact of batch sizes
'Pushing' and 'pulling' in action
The impact of waste
Removal of frustration
You are a subcontractor working for the Manchester Smart Motorway delivery team on prefabricated Gantry legs. This a critical path activity.

The gantry leg consists of parts which are from 5 different suppliers. Each supplier has their own Warehouse/ Cabins.

The Client Highways England expects exceptional quality. You have employed a quality manager to ensure the completed gantry legs are inspected before being delivered to the customer.

The project requires 30 gantry legs every 5 minutes.

Current performance is causing serious upset with Highways England who have complained several times.

The process is too slow and needs to fixed quickly.




Product: Gantry Leg
GOAL!
Lean Awareness Training
To enable the delivery of increasing value to our customer
To provide a basic understanding of Lean Principles & tools
To give you experience of Lean using a practice example
To understand how Lean Process Improvement could be applied to your own processes
To capture existing issues for potential improvement projects
Under worked
Productive and with time to plan
Over-loaded or on the
critical path
Today we want to show how Lean can give us the head-room to move from being over-loaded to being productive and with time to plan
Scenario
The Process
Rules
Each warehouse/ cabin must produce batches of 5

Stay in your work area

Work as fast as you can...management expect this!

No helping slower members of the team

No pre-assembly

Send back defective items for rectification
Roles
Manager
- Managers & encourages team

Data Analyst 1
- Measures 2nd product in 1st batch (2nd one made) and the 10th product in the 2nd batch.

Data Analyst 2
- Time the cycle time of each station (Calculate start of the batch until the end / 5)

Stores/ Materials Handler

Traffic Management
- Transports goods and materials

Inspection:
inspects the products and sends back any defects

Customer:
Customer of the process




As a group…
Run the existing process – batches of 5 items
Assemble at least 30 items
Measures 2nd product in 1st batch (2nd one made) and the 10th product in the 2nd batch.
Measure cycle time
YOU HAVE 5 MINUTES!

How did it go? What were your results?

First Run of Exercise
Lean Overview
Exercise: Creating a Visual Performance Board
Make a visual performance board from the data you have collected.
Waste Exercise: Identify the Waste?
Exercise: Creating a Value Stream Map
As a team develop a value stream map and identify the value and waste.
Applying Lean to the simulation
1. We made sure we understood what we were trying to achieve and what it was that the Customer wanted

2. Reviewed the data to help us see how the process was performing

3. Analysed the process by producing a Value Stream Map

4. Worked as a team, improved the process using the Value Stream Map

Now...

1.Implement the new process and collect data to show improvements

2. Review our performance and celebrate our success

Lean Simulation - Round 2
Building a Lego Ganty Leg
Go to the Value stream map and critique the process to remove waste and rebalance the line

Also decide how will 'pull' the work through the process

'Trial' the new process

When you are ready, lets go for the final run

Assemble at least 30 items
Measure 2nd product in 1st batch (2nd one made) and the 10th product in the 2nd batch.
You have 5 minutes

How did it go? What were your results? How did they compare with the previous runs? Why?


Review of what happened

Did we significantly improve our process?
What were the fundamental changes we made?
How did the second run feel compared to the first?
Did the use of Lean Process Improvement approach and the tools we used help?
Could some of your own work processes be improved using this approach?

Translating this into the real world
Playing with Lego in this room is not directly representative of what you do in your own processes

However...

All processes have common features:
Customers
Suppliers & other stakeholders
People undertaking tasks and activities to provide the customer with a product or service
Value adding activities and waste

Lean can and is being applied to all manner of business types with huge success


MSM Lean Strategy

Collaborative Planning

Visual Performance
Boards

Work Studies

Training

Celebrate success
2015 Strategy:

Developing Capability:
Circa 150 people trained in Lean methods and techniques

Lean engagement:
LCI Summit, LCI NW engagement, HE Practitioner day

Lean Improvement:
11 studies undertaken - £3.5M potential saving
Collaborative Planning and Visual Management embraced by project. “Best we have ever seen”

Sustaining Lean
Link to HE Lean Tracker
Lean MSM Successes so far
Case Study Example
Where could you apply Lean thinking in the future?
What opportunities can you think of that can improve this project?
Katie Jones
March 2016

https://kol.withbc.com/HA-Lean/
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