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Mark Graban
@MarkGraban
www.PracticingLean.com
www.LeanBlog.org
Slides & More:www.MarkGraban.com/LALMS
Reflections on 20+ Years Trying to Get Better at Lean
in Manufacturing & Healthcare
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www.louisebatz.org
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Practicing Medicine
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Practicing Law
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Practicing Lean?
© Nicole Yearly (“chicagozen“ on Flickr), used under Creative Commons License
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Implementing
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Practicing
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Learning
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LearningBy
Doing
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LearningBy
Doing**With a Qualified Coach
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“I’m Jim Pell.I’ve been learning Lean for 25 years.”
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LearningThroughMistakes
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e
We AllMAke
Misteaks
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One ofMy
Mistakes(2004)
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“My” Kanban System
When inventory reaches 2160, take care to Level 4 Meterbody kanban board.
Qty to build: 660 units
Actual Build Qty:
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“My” Kanban System
When inventory reaches 2160, take care to Level 4 Meterbody kanban board.
Qty to build: 660 units
Actual Build Qty:
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Or…
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eansisguidedlyxecuted
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Or…Just not good
at this yet?
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Their Kanban System
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We All StartSomewhere
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eansistakenlyxplained
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“Toyota would tell you to kick the patient out of the
room at 19:59 because you have to keep on takt time.”
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Dunning-Kruger EffectUnskilled and unaware of it: how difficulties in recognizing one’s own incompetence lead to inflated self-assessments – Kruger & Dunning (1999)
100%
0%None Experience Expert
Con
fiden
ce
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We All StartSomewhere
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“Which Lean Tool Should I
Start With?”
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Start from need.
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What problem are we trying to solve?
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“Which Lean Tool Should I
Start With?”
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“Always start with 5S”
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“Always start with 5S?”
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We’ve Always Done it
That Way
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ToyotaProduction
System
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ThinkingProduction
System
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Learn, But Don’t Copy
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eansisguidedlyxecuted
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Right Tool, Wrong Culture
7 am
8 am9 am10 am11 am12 am1 pm2 pm
92
92
92
9292
92
9292
BLOCKS • Plan• Actual• Reasons why
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Right Tool, Wrong Culture
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Right Tool, Wrong Culture
7 am
8 am9 am10 am11 am12 am1 pm2 pm
92
92
92
9292
92
9292
BLOCKS60
60
60
6045
60
1430
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My GM Mistakes• Ergonomic assist• Kanban tooling board• Calling out the manager• Quality or cost?
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1996 Current State at GM
• Worst performing engine plant
• Worst performing part of GM Powertrain
• Worst performing part of GM N.A.
• Worst performing part of GM
• Worst performing automaker
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"We were offering suggestions and getting pushback on safe
staffing, yet being told to reduce the number of pens and pencils.”
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Or…
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eansistakenlyxplained
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“Go ahead and use Lean on that quality problem…
you’ll speed up your quality problem and make bad stuff faster.”
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“Lean will help you to reduce or eliminate [wastes] 1 through 6.
Six Sigma will help you to reduce number 7 [defects].”
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Jidoka Just-in-Time
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“If lots of people are upset, it’s not really TPS.”
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ComplainingAbout
Resistance
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Complaining About Lack ofSustainment
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“We were only holding the gains on about
40 percent of those
[Kaizen Events]”
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Lack ofAdoption?
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“We’ve been implementing Lean
for 5 years… now we’re focusing on
continuous improvement.”
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WhyLean?
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WhyLean?
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90%??
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Why BeBetter at
Lean?
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• Don’t be afraid to make mistakes
• Learn from the mistakes of others
• Try to anticipate possible mistakes
• Make small mistakes to prevent big mistakes
• Don’t keep making the same mistakes
If You’re New to Lean…
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• Share your early mistakes
• Call out “Fake Lean?”
• Be patient & respectful
• Always be a learner, and be making new mistakes
If You’re Experienced…
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• Make sure you’re staying true to Lean without being too dogmatic
• Think about how people might misunderstand what you’re teaching
• Discuss pro-active countermeasures to L.A.M.E. or “Fake Lean”
If You’re Teaching…
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Learn bydoing
Do it right the first time
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Q&A / Contact Info• www.MarkGraban.com • www.LeanBlog.org• [email protected] • Slides & More:
www.MarkGraban.com/LALMS
www.PracticingLean.com