The Soft Stuff is Hard

Lean Manufacturing Implementation Challenges

Lean Manufacturing Implementation Challenges

Outline 1) Senior leadership engagement 2) Engineer and Middle Management engagement 3) Operator and staff engagement
2

Lean Manufacturing Implementation Challenges

1) Senior leadership engagement

Leadership commitment and culture Strategic planning Goal alignment and Customer focus

Lean Manufacturing Implementation Challenges

1.1) Leadership commitment and culture

Traditional Culture Internal Focus Managers Direct Maximise Functional Silos Expert Driven Blame People & Departments Guard Information & Discuss Irregularly Benchmark to Justify not improving just as good Rewards; Individual Supplier is the Enemy Volume lowers cost Lean Culture Customer Focus Managers Enable / Teach Work in Cross Functional Inter-disciplinary teams Process Driven Focus on root Causes Share Information & Discuss Often Strive for Excellence & drive out waste Rewards; Groups Supplier is an Ally Removing waste lowers cost
4

Lean Manufacturing Implementation Challenges

Lean Linkages for Sustained Change

FORMAL STRUCTURE AND SYSTEMS

P
LEAN PHILOSOPHY

C Q

S
PROCESS TOOLS

What does a business need to do to enhance its chances of success?

Lean Manufacturing Implementation Challenges

TAKT TIME PITCH 5S K AIZ EN PULL PHYSICAL LAYOUT CYCLE TIME VALUE STREAM MAPPING STANDARD WORK
Why do lean tools in themselves fail to sustain the lean culture?

LEAN TOOLS
KANBAN WASTE L E V E L IN G ERROR PROOFING VISUAL CONTROLS

Lean Manufacturing Implementation Challenges

Leadership Structure and Purpose
50 40

Business Stategy, Leadership & Goal Alignment Coaching, Daily Problem Solving & Value Stream Projects Responsible & Accountable for performance, problem solving & work area

30

20

L3

10

0 1-Mar 1-May 1-Jul 1-Aug 1-Nov 1-May 1-Jan 1-Jun 1-Oct 1-Apr 1-Dec 1-Jun 1-Sep 1-Feb

Strategic Improvement
50 40

30 20

L2

10

0 1-Mar 1-Jan 1-Jul 1-Aug 1-Nov 1-Oct 1-Apr 1-Dec 1-Sep 1-Feb

Step Change Improvement

50 40 30

1-May

1-Mar

1-Aug

1-Nov

1-Jan

1-Jun

1-Jul

1-Oct

1-Apr

Continuous Improvement

1-Dec

1-Sep

1-Feb

L1

20 10 0

Lean Manufacturing Implementation Challenges

Lean Philosophy Stop to fix problems Go to the gemba (where the truth is) Empower staff to solve problems Correct the problem 24 hours Continuous, small-step improvement Go see, ask why and show respect
8

Lean Manufacturing Implementation Challenges

Lean Manufacturing Implementation Challenges

Preparing the business for Lean Implementation

Short burst of theory

Big chunk of hands-on learning

10

Lean Manufacturing Implementation Challenges

The Sieve
Cumulative Patient Volume Cumulative Patient Type Strategy

6-8%

Make the "green stream" flow Use levelling Eliminate waste

50%

50% Work closely to align with Green products Work on reasons stopping yellows going in to Green streams

70% 95% 100%

Institutional waste Remove non-value adding complexity

Requires involvement of all stakeholders 99% 100%

11

Lean Manufacturing Implementation Challenges

Develop a rollout plan

12

Lean Manufacturing Implementation Challenges

Sample implementation plan

13

Lean Manufacturing Implementation Challenges

1.3) Goal alignment and customer focus

14

Lean Manufacturing Implementation Challenges

1.3) Goal alignment and customer focus To customers (external/internal) To company and business goals Meaningful for the teams

15

Lean Manufacturing Implementation Challenges Leadership coach/mentor/teacher

Why is Leadership imperative to a successful lean implementati on?

SPIRIT of Lean Mentorship:

If the learner hasnt learned, the teacher hasnt taught
John Shook
16

Lean Manufacturing Implementation Challenges

2) Engineer and Middle Management Engagement

Value stream projects Work on the right problems at the right time Problem solving
17

Lean Manufacturing Implementation Challenges

2.1) Value stream projects

18

Value Add (Typically 5-15% value add) IN

OUT

Non Value Added Waste Waiting Overproduction Rejects Motion Processing Inventory Transport Staff Utilisation

19

Lean Manufacturing Implementation Challenges

2.2) Work on the right problems at the right time

20

Lean Manufacturing Implementation Challenges

2.3) Problem Solving

What challenges do Engineers face in implementing lean?

21

Lean Manufacturing Implementation Challenges

3) Operator and staff engagement

Go see, show respect and ask why Mini business Process confirmation

22

Lean Manufacturing Implementation Challenges

3.1) Go see, show respect and ask why

Teaching Is Our #1 Job

Core value respect for people

23

Lean Manufacturing Implementation Challenges

3.2) Mini business

Set 20-50% improvement targets

24

Lean Manufacturing Implementation Challenges

3.3) Process confirmation

Process Confirmation Sheet:
Dedicated time daily

Go, Look, See

25

Lean Manufacturing Implementation Challenges

Summary
Active leadership commitment Choose the right projects so they are strategically aligned Go see, show respect and ask why

26

Lean Manufacturing Implementation Challenges

Thank you and Questions

27