why lean doesn't work - ok · pdf filewhy lean doesn’t work ... • explain to...
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Why Lean Doesn’t Work
A Conversation for Company Leaders
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Industrial Solutions - ISI • Consulting firm based out of Tulsa, OK • Colin Reed, Owner • Established in 1997 • Full-service lean manufacturing and
management consulting firm - Training, Facilitation, Consulting
• Served hundreds of companies • www.isiworld.net
Industrial Solutions – ISI www.isiworld.net
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Agenda
• Quick Diagnostic • Your Role as Leader • How to Make Lean Work
• Strategy & Alignment • Vision • Communicate & Motivate • Develop Your People
Industrial Solutions – ISI www.isiworld.net
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Could it be… “ Significant effort and dollars are invested in lean initiatives each year in manufacturing plants across the United States. These investments can yield significant production and profitability gains if done properly. However, it is not uncommon for these initiatives to fail because of one or several key factors in management preparation for the lean journey. ”
Jason Platt, President, Praestar Technology Corp
Industrial Solutions – ISI www.isiworld.net
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What Changes Need to Occur?
Management’s • Focus • View of labor, reward and compensation • Organizational structure/chain of command • Methods of evaluating decisions/results • Data collection and analysis
Industrial Solutions – ISI www.isiworld.net
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In Other Words
The “Culture” is going to be affected if you try to implement lean manufacturing.
Industrial Solutions – ISI www.isiworld.net
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“Lean is 40% about the tools, 60% is about developing people”
Industrial Solutions – ISI www.isiworld.net
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Quick Diagnostic
• Please answer the questions on the
sheet in front of you
• Calculate your score
• 5 minutes
Industrial Solutions – ISI www.isiworld.net
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• Next, please turn over the sheet
• List the 10 things you spent the majority
of your time on last week at work
• 5 minutes
Quick Diagnostic
Industrial Solutions – ISI www.isiworld.net
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Priority Check
Were a majority of those lean activities?
• Is there a disconnect?
Industrial Solutions – ISI www.isiworld.net
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If you wrote, “went to the shop floor, or Gemba”,
• Did you go without a non-lean mission or task to
do?
• Did you go just to listen?
• Did you actually stop to observe the work?
Priority Check
Industrial Solutions – ISI www.isiworld.net
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If you went to the gemba, there is no way everything is working perfectly… …that doesn’t happen at any company.
Priority Check
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Violations of:
• Kanban systems
• 5S rules
• System audits
• Inventory levels
• Standard work
Did you make on the spot corrections to…
Observations of:
• Stagnant Cross-training
charts?
• Ancient A3’s?
• Unacceptable changeover
times? • Procedure abandonment?
Priority Check
Industrial Solutions – ISI www.isiworld.net
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Sustainment
Over time, lean gains in • Processes • Systems • Culture • Lead times • Training levels
Atrophy
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A Key? The key to the Toyota Way and what makes Toyota stand out is not any of the individual elements, but, what is important is having all the elements together as a system. It must be practiced every day in a very consistent manner, not in spurts.
Taiichi Ohno
Industrial Solutions – ISI www.isiworld.net
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We make time for what is important to us.
Priority Check
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Is lean truly important to you?
If you don’t prioritize Lean, who will?
Priority Check
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Think about it: If you eliminated 20% of your waste, you could double your production capacity. Isn’t that cheaper than: • Adding a 2nd shift? • A new building or plant? • Outsourcing work you could do yourself? • Losing dissatisfied customers?
How could you not pursue lean to perfection?
Industrial Solutions – ISI www.isiworld.net
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Leading by Example Leaders need to: • Lead the way • Walk the walk • Live the lean life • Be dedicated to approach every decision
from the lean viewpoint
Industrial Solutions – ISI www.isiworld.net
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If we have Leaders that are… • Lean students first and foremost • Lean visionaries second • Lean motivators that keep all of us on track • Lean teachers • Lean practioners ALWAYS!
• Leading by EXAMPLE
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We will have followers who are..
• Lean students • Lean practioners • Lean teachers- in their own realm • Lean motivators- at their point of impact • Lean visionaries- ultimately it is some of
these very people who will ultimately carry the torch for the future
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Ask yourself:
Can you: • Explain to an operator how lean will help
make his job easier in intimate detail? • Conduct a 5S audit? • A Systems Audit? • Feel comfortable observing a cell for an
hour, know what to look for, know what action to take?
• Lead an improvement event?
Industrial Solutions – ISI www.isiworld.net
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The Eight Deadly Wastes Overproduction Making what is unnecessary, when it is unnecessary, and in unnecessary amounts. Inventory Goods that are being retained for any length of time, inside or outside the factory. Transportation Any transport or transference of materials, parts, assembly parts, or finished goods, from one place to another for any reason. Defects The defects themselves, the costs of inspecting for defects, responding to customer complaints, and making repairs. Processing Waste Operations and processes that may not be necessary. Motion Waste Movement that is not really needed to perform an operation. Waiting Idle time: Human and/or machine waiting. Under-Utilized People Not using the creative and problem-solving ability of people. Industrial Solutions – ISI www.isiworld.net
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Quick Changeover
Standardized Work
Batch Reduction Teams
Quality at Source
5S System Visual Controls Plant Layout
POUS
Cellular/Flow Pull/Kanban TPM
VSM
Culture of
Continuous Improvement
Industrial Solutions – ISI 10404 E. 55th Pl., Suite G.
Tulsa, OK 74146 918.280.9051
www.isiworld.net
The Lean Toolbox
Industrial Solutions – ISI www.isiworld.net
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So, if you’ve got a Lean initiative:
Why is change so hard?
• We focus on the externals of lean tools • We miss the underlying dynamic of how
an organization thinks and processes information
Industrial Solutions – ISI www.isiworld.net
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Bad Assumptions
• People function on a rational level • Change is good and automatic • Company culture is easy to change
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Culture
5-S QCO Cells Pull
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Where Does Lean Reside?
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How Do You Make Lean Work?
• Strategy and Alignment
• Vision
• Communicate and motivate
• Develop your people
Industrial Solutions – ISI www.isiworld.net
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Michael Balle answer to; ‘Can middle management drive the Lean initiative?’ - “It might be possible, but, personally I've never seen it happen. I even run into trouble when I work with the COO and the CEO is not into lean thinking. In lean we call this the canoe problem.”
Make Lean Work: Strategy and Alignment
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Management Alignment – High Agreement • Must come from top, then all levels of
leadership • Management team has to be pulling together
• Must own the model • Must be committed to each other’s success
Make Lean Work: Strategy and Alignment
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Management Alignment – High Agreement • Just saying “I support Lean” is not enough, as a
Leaders we need to live it • Lean is about creating a learning environment,
where people can flourish in a Culture of Solving Problems
Make Lean Work: Strategy and Alignment
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Management Alignment – High Agreement
Make Lean Work: Strategy and Alignment
NASA Apollo Missions
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Culture Change • Culture change requires a strategy and top
level commitment, or your efforts will fail • Real change occurs at the process level when
people start to think differently
Make Lean Work: Strategy and Alignment
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Culture Change – at your company, • What is people’s view of their work? • What is important to management? • How does the place look?
Make Lean Work: Strategy and Alignment
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Make Lean Work: Strategy and Alignment
A Value Stream Flows Counter to the Current Culture • Flow in a value stream is fundamentally different than
the processes in traditional organizations that are organized along functional boundaries
• Most of the effort in traditional companies is expended in managing the interface between the boundaries
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Make Lean Work: Strategy and Alignment
State that we are moving to data based decision making, not opinions.
• Performance must be measured in continuous, rapid feedback loops
• Audits, Systems Audits
• Self-interests must be linked to clearly defined key performance indicators (KPI’s)
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From those who’ve been there...
“We should have started the journey in each of the divisions (Sales, Engineering, Production) at the same time, so the greater value stream is maximized and not segmented.
Clay Davis
Value-stream Manager McElroy Mfg.
Make Lean Work: Strategy and Alignment
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How Do You Make Lean Work?
• Strategy and Alignment
• Vision
• Communicate and motivate
• Develop your people
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Make Lean Work: Vision
Create a Vision • Simply stated • Brief, but eloquent
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Make Lean Work: Vision
A Lean Enterprise Looks Different
Defining The Vision
Workplace Order and Cleanliness
JIT Production, minimum waste
Superior Quality
Continuous Improvement
Culture Empowered
Teams aligned with strategy
Visual Management
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Make Lean Work: Vision
Lean Enterprise Vision Primary Goals • Creating Flow along Value Streams in response
to customer demand • Eliminating Waste in the value stream • Encompassing a comprehensive approach to
the entire organization - Changing the Culture
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Learning Organizations • Organizations where people continually expand
their capacity to create the results they truly desire • Where new and expansive patterns of thinking are
nurtured, • Where collective aspiration is set free • Where people are continually learning how to learn
together
Attribution: http://www.citehr.com/14342-summary-senges-famous-book-fifth-discipline.html#ixzz3EdVg2lJz Peter Senge's The Fifth Discipline
Make Lean Work: Vision
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Before After % Imp.
Operator Foot Travel 4224' 63' 98.5%
Set-up Time (min) 185 9:50 94.6%
ISI Lean Implementer Class
Held at CMP Corp, Moore, OK
Quick Changeover Workshop:
GT202 Mill
September 22-23, 2014
This machine averages 3 set-ups per week = 9 more hours/week availability
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Make Lean Work: Vision
“By the way, we are going to replicate the 10-minute exchange of dies next Monday morning. We are also committing to implement 10 minute changeovers in all cells by the end of 2015.”
Gerry Raubach Director of Operations CMP Corp. September 26, 2014
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How Do You Make Lean Work?
• Strategy and Alignment
• Vision
• Communicate and motivate
• Develop your people
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Push to keep the initial enthusiasm going • Must come from top, then all levels of
leadership • Be in on or lead kaizen events
Make Lean Work: Communicate & Motivate
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Motivate through Standard Work expectations • “Trust, but Verified” • Audits: 5S, Set-ups, procedures, kanban
systems • When changes are made, ensure they stick
• Systems Audits • Find breakdowns of standards pro-actively • Measure for performance
Make Lean Work: Communicate & Motivate
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Manager, a Coach?
“The manager is a servant. His master is the institution he manages and his first responsibility must therefore be to it… A manager's task is to make the strengths of people effective and their weakness irrelevant - and that applies fully as much to the manager's boss as it applies to the manager's subordinates.”
Peter Drucker
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Make Lean Work: Communicate & Motivate People must believe there is a need for change This is achieved through: • Training • Communication • Awareness • Metrics
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Make Lean Work: Communicate & Motivate
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Make Lean Work: Communicate & Motivate
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Employees • How do you reward them? • What is your break-room like?
• Does it attract people to it? • Do you eat there? Would you?
• Do they see their ideas implemented immediately?
Make Lean Work: Communicate & Motivate
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Make it Happen • Do kaizen events on a strategic value-stream to
jump start activity • Don’t find excuses to not improve
• ISO or API cert., expansion, new product, too busy
• “We’re training management first.” • Only process changes will test their
knowledge and commitment
Make Lean Work: Communicate & Motivate
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How Do You Make Lean Work?
• Strategy and Alignment
• Vision
• Communicate and motivate
• Develop your people
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Make Lean Work: Develop Your People
Train, Train, Train! “We’ll spend all that money to train people, and they’ll just leave.” • You will never progress from where you are • Who stays where they aren’t valued?
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Make Lean Work: Develop Your People
Xenon Engine Deep Space 1
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Train, train, train!
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First Line Managers/Supervisors
Mission Statement
Strategic Objectives
Strategy Deployment
The Processes
Present
Future C E O
Activities with Connections & Flows
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Concluding Statements • Nothing of any significance will ever happen
without the commitment and drive of top management
• The landscape is strewn with the wreckage of companies that failed to understand the necessity of culture change
• Lean Manufacturing is as much a state of mind as it is a process for excellence in manufacturing
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Contact Information:
918-280-9051
www.isiworld.net
Thank You!
Industrial Solutions – ISI www.isiworld.net