Insights into Implementing Lean Principles

1. Large Scale Program Transformation using Lean Practical Insights in Implementing Lean Principles
By
Krishnamurty VG Pammi
Agile Coach
IVY Comptech

2. 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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3. 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

4. 4
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

5. Lean Principles Implemented
5
SL #
Lean Principle
1
Value Stream Mapping
2
Takt Time
3
Work Load Levelling
4
SMED
5
5S
6
Visual Control

6. 6

7. 7

8. 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
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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.

9. 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
CONFIDENTIAL© Copyright 2005 Wipro Ltd
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Application
Complexity
Analysis
Resource
Profiling
Work Allocation

10. 10
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%
CONFIDENTIAL© Copyright 2005 Wipro Ltd
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11. Lean Tenet : 5S
11
Utilized 5S to fasten the media search and media availability through out the Test Pass.
CONFIDENTIAL© Copyright 2005 Wipro Ltd
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12. Lean Tenet: Visual Controls
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13. 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

14. 14
By
Krishnamurty VG Pammi
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