tips for launching a successful lean journey -...
TRANSCRIPT
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Tips for launching a
successful LEAN journey February 10th, 2017
Ian Marshall – Lean Champion
Canadian Manufacturers & Exporters
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LEAN Definition
“LEAN is an Operations’
Strategy with a new set
of Values to Engage
People in Continuous
Improvement” Jeffrey Liker, author of The Toyota Way
Ian Marshall – Canadian Manufacturers & Exporters
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LEAN Transformation
“Managers must change from
the habitual focus on results to
a different and less obvious
focus on process”
Ian Marshall – Canadian Manufacturers & Exporters
David Mann, author of Creating a Lean Culture
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Ian Marshall – Canadian Manufacturers & Exporters
http://paulakers.net/books/2-second-lean-resources/2sl-our-top-lean-videos
Paul Akers – FastCap.com
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• Communicate the “why”
• Create the environment
• Deliver results
Ian Marshall – Canadian Manufacturers & Exporters
Three things to consider…
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Communicate the “why”
Ian Marshall & Carrie Schroeder – Canadian Manufacturers & Exporters
Three key human motivators:
Autonomy e.g. ‘FedEx day’: one innovation day
per quarter or ‘genius hour’: one
innovation hour per week
Mastery Making progress in meaningful work
Purpose
It starts with the “why”…
Daniel Pink
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Communicate the “why”
Ian Marshall – Canadian Manufacturers & Exporters
“Décor’s mission is to
create cabinets people
love, bring light to the
world and the community,
to build life into people’s
lives and to leave behind
more then we take”
Larry Dyke, President & CEO, Décor Cabinets
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• Communicate the “why”
• Create the environment
• Deliver results
Ian Marshall – Canadian Manufacturers & Exporters
Three things to consider…
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Create the environment
• Go See
• Ask Why
• Show Respect
Fujio Cho, Chairman of Toyota
Ian Marshall – Canadian Manufacturers & Exporters
Three keys to leadership:
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Create the environment
“It’s better to ask the
right question, than
to give the right
answer”
“The moment you tell
someone to do
something, you take
away their
responsibility” John Shook, President Lean Enterprise Institute
Ian Marshall – Canadian Manufacturers & Exporters
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Create the environment
Core Values: • People
• Customers
• Kaizen
Employee Expectations: • Tell the truth
• Be fair
• Try new ideas
• Ask why
• Keep your promise
• Do your share
Ian Marshall – Canadian Manufacturers & Exporters
Art Byrne, author of The LEAN Turnaround
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• Trust – give employees a voice
• Put people in control…unleash the power
• Clarify team purpose and strategy
– Make it visible
– Measure what matters
– 10 second rule
• Mindset drives capability
• Show appreciation…
Ian Marshall – Canadian Manufacturers & Exporters
Create the environment
Billy Taylor The Goodyear Tire & Rubber Company
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Create the environment
Ian Marshall – Canadian Manufacturers & Exporters
LEAN Greenbelt Kaizen Blitz
Duxton Windows & Doors
CME LEAN Training:
• Intro to LEAN
• LEAN Yellowbelt
• LEAN Greenbelt
• LEAN Blackbelt
• LEAN for Leaders
• Training Within Industry
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• Communicate the “why”
• Create the environment
• Deliver results
Ian Marshall – Canadian Manufacturers & Exporters
Three things to consider…
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Deliver results
“Begin with stability producing lean
projects and use them to prepare the
ground for lean management”
Ian Marshall – Canadian Manufacturers & Exporters
David Mann, author of Creating a Lean Culture
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Deliver results
Ian Marshall – Canadian Manufacturers & Exporters
Before After
LEAN Greenbelt two-day 5S Kaizen Blitz
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Ian Marshall – Canadian Manufacturers & Exporters
Deliver results
Simple Material Replenishment Systems
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Ian Marshall – Canadian Manufacturers & Exporters
Sales Engineering
Planning
Purchasing Production
Parts Assembly Paint
Finishing Shipping
C
a
s
h
Q
u
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t
e
Deliver results
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Deliver results
Ian Marshall – Canadian Manufacturers & Exporters
“Wherever there is a customer, there is always a value stream… your challenge is to see it”
Jim Womack – author of Lean Thinking
Bottlenecks
Cycle Time
Issue Root Cause Solution
Process Step
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Deliver results
Ian Marshall – Canadian Manufacturers & Exporters
“Visual controls
connect people to
processes and reflect
adherence”
David Mann, author of Creating a Lean Culture
Hour By Hour Actual to Plan Progress Chart
“The status of virtually every process should
be visible in lean management”
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Deliver results
Ian Marshall – Canadian Manufacturers & Exporters
Traditional management:
“Did you meet the
schedule?”
Lean management:
“What caused the problem
that interrupted the
process and who will do
what to fix it?” David Mann, author of Creating a Lean Culture
Daily Huddle – Shift Plan & CI
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Deliver results
“The closer your position to
Production, the more time you should
spend watching the process”
Ian Marshall – Canadian Manufacturers & Exporters
Leaders Role:
- Establish the process
- Monitor adherence
- Improve the process
David Mann, author of Creating a Lean Culture
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• Communicate the “why”
• Create the environment
• Deliver results
Ian Marshall – Canadian Manufacturers & Exporters
Three things to consider…