lean workshop 2015

Introduction to LeanEdmund J. Sutcliffe @EdmundSutcliffe

Simon Carter @smescrater

A bad system will beat a good person every time.

-W. Edwards Deming

What is Lean?

What is Lean?

Perfect Value

What is Lean?

Perfect Value

Perfect Process

What is Lean?

Perfect Value

Perfect Process

Zero Waste

Intelligent laziness.

What is Lean?

Why Go Lean?

Why Go Lean?

Run the Business

Why Go Lean?

Grow and Transform

Run the Business

Why Go Lean?

Grow and Transform

Run the Business

Lean Operational Excellence

Why Go Lean?

Grow and Transform

Run the Business

Run the Business

Lean Operational Excellence

Why Go Lean?

Grow and Transform

Run the Business

Run the Business

Lean Product Development

Lean Operational Excellence

Why Go Lean?

Grow and Transform

Run the Business

Run the Business

Grow and Transform

Lean Product Development

Lean Operational Excellence

The Building Blocks of Lean

Culture

The Building Blocks of Lean

Culture

Flow

The Building Blocks of Lean

Systems ThinkingMistake

AvoidanceCustomer Insight

Culture

Flow

The Building Blocks of Lean

Behaviour

Systems ThinkingMistake

AvoidanceCustomer Insight

Culture

Flow

The Building Blocks of Lean

Constancy of Purpose

Knowledge Management

Continuous Improvement

Behaviour

Systems ThinkingMistake

AvoidanceCustomer Insight

Culture

Flow

Flow

The Coin Game

Sticker Colour Role

Green Product Owner

Blue Analyst Manager

Violet Analyst

Pink Development Manager

Red Developer

Orange Test Manager

Yellow Tester

The Coin Game

Analyst Developer Tester Product Owner

Flips coins in a batch then moves batch to next person. Repeats for all batches.

Manages the process. Records time taken for entire batch to be completed. Records time taken for each batch

Times each batch. Time starts once first coin is flipped and ends once last coin is flipped. Reports batch time to product owner.

Times each batch. Time starts once first coin is flipped and ends once last coin is flipped. Reports batch time to product owner.

Times each batch. Time starts once first coin is flipped and ends once last coin is flipped. Reports batch time to product owner.

Flips coins in a batch then moves batch to next person. Repeats for all batches.

Flips coins in a batch then moves batch to next person. Repeats for all batches.

The Coin Game Actual Results

R1(batch size 20)

R2(batch size 5)

R3(batch size 2)

Analysis 12.475 14 13.3

Development 10.66 17.045 14.275

Test 12.75 16.22 14.7

Product Delivery 43.615 23.6375 17.1775

The Coin Game Debrief

● Small batch sizes were more fault/defect tolerant

● Smaller batches increased phase time but decreased overall time

● Once a sense of flow has been established great results can be reproduced consistently

● Empowering your team leads to innovative results!

Value Stream Mapping

Nature does constant value stream mapping.It's called evolution.

How do you do it

Gemba walks

Scientific thinking (PDCA)

Kanban

Ticketing system

Lean Behaviours

Lean Behaviours

Know how the business serves the

customer

Lean Behaviours

Know how the business serves the

customer

Focus on process and

results

Lean Behaviours

Know how the business serves the

customer

Show a continuous

improvement mindset

Focus on process and

results

Lean Behaviours

Know how the business serves the

customer

Show a continuous

improvement mindset

Demonstrate an understanding of the value stream at a macro and micro

level

Focus on process and

results

Lean Behaviours

Know how the business serves the

customer

Show a continuous

improvement mindset

Demonstrate an understanding of the value stream at a macro and micro

level

Focus on process and

results

Create a culture to sustain

improvement

Lean Behaviours

Know how the business serves the

customer

Show a continuous

improvement mindset

Build ability in people

Demonstrate an understanding of the value stream at a macro and micro

level

Focus on process and

results

Create a culture to sustain

improvement

Waste

Only the last turn of a bolt tightens it—the rest is just movement

-Shigeo Shingo

The Standard Pig

One of the main types of waste to avoid is waste by variation. The next activity will demonstrate how this can be avoided simply.

The Standard Pig Actual Results 1

Images courtesy of @RyzJenvey

The Standard Pig Actual Results 2

Images courtesy of @RyzJenvey

The Standard Pig Actual Results 3

Images courtesy of @RyzJenvey

The Standard Pig Debrief

● Round One○ Many different pigs produced○ Which is the right one?

● Round Two○ Less variation in pigs○ Standard instructions helped

● Round Three○ Much less variation○ Diagram and clear instructions reduce

waste

Who are your Customers?

Oh, they may be weary

customers get weary

All the problems that they have to address, yeah yeah

But when they get weary

Try a little tenderness, yeah yeah

Who are your Customers?

You know they're waiting

Just anticipating

For systems that'll never, never, never, never cause stress, yeah yeah

But while they're there waiting, without them Try a little tenderness (that's all you gotta do)

AQ&