lean workshop 2015
TRANSCRIPT
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&