Download - Robert Bruce - Driving Enterprise Excellence
ROBERT BRUCEManaging Director Australia
Vice President Manufacturing and Supply Chain (MoW)Vistaprint
The Spirit of LeanHow to successfully transcend industries with Lean?
For help along the way…Thankyou!
Dr. Hauke Hansen
Andy Kelsall
Agenda• Who are Vistaprint?• A typical Lean Story• The “Spirit of Lean”• Our Lean Journey… so far• Q&A & Wrap Up
Who are Vistaprint?We are global…• 14 offices in 12 countries• 25 localized websites• Serving customers in 130 countriesWe are growing rapidly…• We have grown from 1 to 4,000 employees• We serve over 13 million customers per year• We have grown annual revenue to over $1.4BWe are transforming a market…• We make it easy for micro businesses to
create professional marketing materials (previously only available/affordable to large companies)
Our disruptive business model
Vistaprint
Volume
UnitCost
Low Volume Markets
High VolumeMarkets
A typical “Lean” story
TOYOTATPS
COMPANY A
A.P.S.6 SIGMA
5S
ANDON
KAIZEN
KANBAN
VSM
5 WHYSMED
HR-HR
PULL
We are Lean?KAIZEN
KANBAN
SIGMA
SMED
VSM
5S
PULL
ANDON
5 WHY
HR-HR
SMED
JIT
KAIZEN
KANBAN
SIGMA
PULL
JIT
Unsuccessful companies focus solely on the appearance of the fruit
5SHR-HR
SMEDVSM5 WHY
ANDON
We are C..Lean?
KAIZENKANBAN6 SIGMA
VSM
PULL
ANDON
5 WHY
5SHR-HR
SMED JIT
Fertile Ground for Lean
Unsuccessful companies solely focus here
Successful companies focus here
How do we feed the soil for growth?• Does the Lean spirit exist from the top down?• Does the company have Business Policy Deployment?• Does cooperation between departments exist?• Are roles and responsibilities clear?• Are employees valued for their works?• Are systems improved over time to become more stable and
predictable?• How are problems kept from recurring?• Do managers, supervisors and team leads have the ability to teach
or coach?• Do management often go to shop-floor to practice “Gemba Walk”?
Fertile Ground for Lean
The Spirit of Lean
Our Lean Journey
Our Vision for Deer Park
To become Australia’s best custom
manufacturer
Simple LogicInput
(Resource)Output
(Results)
• People• Materials• Machines /
Equipment
• Customer Satisfaction• Employee Satisfaction• Employee
Development• Profitability ($)• Contribution to society• Enduring Legacy• Development of people
Method(Process)
=• Lean tools• Lean Systems• Lean processes
Launch Principles..the critical first 90 days• Engage the people
• Safety First
• Steal with Pride
• KISS (Keep it Simple, Stupid)
• Communicate, Communicate, Communicate
• Foster a CI Mindset &
• Iterate rapidly
Fertile Soil at Deer Park• Does the Lean spirit exist from the top down?• Does the company have Business Policy
Deployment?• Does cooperation between departments exist?• Are roles and responsibilities clear?• Are employees valued for their work and ideas?• Are systems improved over time to become more
stable and predictable?• How are problems kept from recurring?• Do managers, supervisors and team leads have the
ability to teach or coach?• Do management often go to shop-floor to practice
“Gemba Walk”?
Policy Deployment
PDCA in Value Streams
16 ideas implemented per person per annum
5S as a means to conduct Standardised
Work
Sustaining Lean Education for ALL• Educate all the team• Develop systems and tools• VPS was born
Some incredible results
6
Shingo as our directional guide
Acknowledging reality vs. Shingo
• Seeing reality with humility • 15 Areas of opportunity
Shingo can’t be just about “The Prize”
• An enduring and truly world class vision point for sustaining growth and achieving success
• Shingo painted a picture of the type of company we all wanted to work for
• The “most rigorous assessment in the world” for a reason….hard to achieve because it’s worth achieving
• Not like any other assessment“If it was just about the
prize, that alone, wouldn’t be enough to sustain the
effort..”
Triple landmark achievement
• First Australasian Plant
• First Print Company Globally
• Youngest Plant Ever
My greatest joy is seeing the team succeed
Our challenge today..
• Australia is a high labour cost country
• Saturated yet relatively small local market
• Reduction in revenues• Global pressures and the need to
work smarter• ….familiar story?• The Lean journey has just begun….
Can Lean really evolve & transcend from
Automotive into a Print setting?
The Spirit of Lean can transcend industriesWhere to
next?
6+ Shingo prizes
1 Shingo Award yet early in the
journey
Thankyou• Questions