If you're a beginner at LEAN performance improvement, this presentation will break down the basic concepts of process mapping, waste identification, and tests of change.
2. Have you ever attended a LEAN training?
Maybe you started out intrigued…
3. …But then you were quickly bombarded
with completely unrecognizable
Japanese terminology.
Have you ever attended a LEAN training?
4. The consultant was saying “gemba”…
Have you ever attended a LEAN training?
5. …And you were hearing:
Have you ever attended a LEAN training?
6. The consultant was saying “poka-yoke”…
Have you ever attended a LEAN training?
7. …And you were hearing:
Have you ever attended a LEAN training?
8. The next thing you know…
You’re completely behind in class.
You hate LEAN.
You resent your boss for putting you
through this.
9. The good news?
(A) You’re a normal human being.
(B) You probably just didn’t have the right instructor.
10. The good news?
Though there are many LEAN tools out there,
let me break down some of the basic concepts
with a simple process map.
Give me about 10 minutes…
(A) You’re a normal human being.
(B) You probably just didn’t have the right instructor.
11. Plain and simple:
LEAN is all about eliminating waste
and adding more value to your customer.
12. Plain and simple:
LEAN is all about eliminating waste
and adding more value to your customer.
Now, it’s time for an example…
13. Say you’ve got this process…
Jesse’s morning production of coffee
14. And it looks something like this…
Jesse’s morning production of coffee
Alarm
rings
Jesse
hits
snooze
Alarm
rings
Jesse
turns off
alarm
Jesse walks
downstairs
Jesse opens
coffee
machine
Jesse
discards
old filter
Jesse opens
pantry door
Jesse pulls
out filter
and coffee
Jesse fills
coffee
machine
Jesse takes
pot to
kitchen sink
Jesse fills
pot with
water
Jesse pours
water in coffee
machine
Jesse
hits start
Jesse
waits 5
minutes
Coffee!
15. And it looks something like this…
Jesse’s morning production of coffee
Alarm
rings
Jesse
hits
snooze
Alarm
rings
Jesse
turns off
alarm
Jesse walks
downstairs
Jesse
opens
coffee pot
Jesse
discards
old filter
Jesse opens
pantry door
Jesse pulls
out filter
and coffee
Jesse fills
coffee
machine
Jesse takes
pot to
kitchen sink
Jesse fills
pot with
water
Jesse pours
water in coffee
machine
Jesse
hits start
Jesse
waits 5
minutes
Coffee!
Believe it or not, we could break
down these steps even further.
Let’s stay at a high level to learn!
16. Why improve it?
While the system technically works
(i.e. the coffee gets made), wouldn’t it be great
if I could spend less time making coffee and
more time doing something I love (i.e. sleep)?
17. Why improve it?
Let’s clean up the process!
While the system technically works
(i.e. the coffee gets made), wouldn’t it be great
if I could spend less time making coffee and
more time doing something I love (i.e. sleep)?
18. Identifying waste
In our example, waste will be any step that does not transform my cup of coffee.
In other words:
Waste = non-value added time
19. Identifying waste
Waste can show up in different ways, including (but not limited to):
• Transportation
• Rework
• Extra-processing
• Waiting
• Underutilization of people
• Excess products/materials
• Overproduction
• Excess motion
20. Identifying waste
Waste can show up in different ways, including (but not limited to):
• Transportation
• Rework
• Extra-processing
• Waiting
• Underutilization of people
• Excess products/materials
• Overproduction
• Excess motion
It’s OK if you don’t know what each type means yet-
we’ll run through a couple examples now!
21. Identifying necessary waste
Example:
Walking downstairs does not transform my
cup of coffee.
→ This transportation is technically waste.
Yet, I’m not willing to put my coffee pot
inside my bedroom.
→ Thus, this is necessary waste.
22. Identifying unnecessary waste
Does my alarm clock really
need to sound twice? No.
Extra-processing
Do I need to throw out the
filter from the day before? No.
Rework
Do I need to wait for
the pot to brew? No.
Wait Time
23. Identifying unnecessary waste
Does my alarm clock really
need to sound twice? No.
Extra-processing
Do I need to throw out the
filter from the day before? No.
Rework
Do I need to wait for
the pot to brew? No.
Wait Time
With some creativity, all of these steps can be
reduced or eliminated without altering
the creation of my morning cup o’ joe.
24. Removing unnecessary waste
This is where the fun comes in!
You get to design small experiments to remove
non-value added time (waste) in your process.
25. Experiment 1
You set the alarm for the later of the two times (provided you normally get to
work on time), and place the clock close to your bedroom door.
Your hypothesis: if you fully have to get out of bed to silence your alarm, you
won’t go back to sleep. Then, you can head straight downstairs to the kitchen.
You’ll eliminate one of the two alarms!
26. Experiment 2
After you brew your coffee, you can throw out the used filter and grounds on
your way out the door.
Your hypothesis: if you can remember to take this step the day you brew the
coffee, you will prevent the unnecessary step (with extra transportation) on
the next day.
27. Experiment 3
While preparing tomorrow’s lunch, you’ll program your coffee pot for
automatic brewing the next morning.
Your hypothesis: by programming your coffee pot at the same time as your
alarm clock, you will not need to wait for the coffee to brew.
28. Can you think of other experiments?
There are other forms of waste in the process and
countless ways to try to address them!
Alarm
rings
Jesse
hits
snooze
Alarm
rings
Jesse
turns off
alarm
Jesse walks
downstairs
Jesse
discards
old filter
Jesse opens
pantry door
Jesse pulls
out filter
and coffee
Jesse fills
coffee
machine
Jesse takes
pot to
kitchen sink
Jesse fills
pot with
water
Jesse pours
water in coffee
machine
Jesse
hits start
Jesse
waits 5
minutes
Coffee!
Jesse opens
coffee
machine
29. Your experiments may or may not work
LEAN is not about getting things right the first time.
It’s about experimenting and learning from your mistakes.
LEAN is about continuously striving to do better.
30. Ready to learn more?
To find out about additional LEAN tools and how they can transform your work,
check out http://jessefavre.com today!
