practical implementation of lean practices to improve
TRANSCRIPT
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Practical Implementation of Lean Practices to Improve Small / Medium Sized Businesses’ Productivity
Nick Brownsword 21st May 2020
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Agenda• Definition of Lean• Two slides of theory!• Practical examples of what lean practices look like
© Productivity People Ltd 2019
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Definition - Lean is not:• A cost cutting programme• A programme to reduce headcount• A project we are working on this year• Only applicable to manufacturing operations• Something that is delegated to the shop floor• A programme run by external consultants• A soft approach with intangible outcomes
© Productivity People Ltd 2019
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Definition - Lean is:• An approach to eliminating all forms of waste within
a business• A philosophy or a way of thinking• A journey that doesn’t end• Led from the top of the organisation• Engages everyone across a business• Develops the skills and capabilities of the team• Creates a work environment where individuals are
willing to give their discretionary effort• Delivers improved business performance
© Productivity People Ltd 2019
Waste caused by defects or
rejects
Waste caused by unnecessary
movement
Waste caused by inappropriate
processing
Waste caused by waiting
Waste caused by transport
Waste caused by overproduction
Waste caused by unnecessary
stock
Kaizen
Source: Competitive Capabilities International (CCI) TRACC
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Best Practices
Leading Change
Teamwork 5S Visual Workplace
Standard Work
Proc
ess/
Mat
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l Flo
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Plan
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Proc
urem
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Tran
spor
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Health and Safety
WORLD’S BEST
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Problem Solving
TPM
/ As
set C
are
Chan
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ver t
ime
redu
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War
ehou
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Busin
ess P
roce
sses
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Practice – Performance Model
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Best Practice – What Does Good Look Like
LEADING AND MANAGING CHANGE
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Vision
Daily Activities
Strategy Deployment – connecting teams to the Vision
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Leading and Managing Change – Best PracticeBe
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A3 Business Plan
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Best Practice – What Does Good Look Like
HEALTH AND SAFETY
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Health and Safety
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Best Practice – What Does Good Look Like
5S – WORKPLACE ORGANISATION
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5S
“Our factory is the best selling tool we have” – Marketing Manager
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© Productivity People Ltd 2019
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Best Practice – What Does Good Look Like
VISUAL MANGEMENT
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Visual Management – Best PracticeBe
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Visual Management – Best PracticeBe
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Visual Management & ProductivityAre we in
spec?Are we in
spec?
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Manual Planning and Real Time Tracking
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• Daily targets by product• Tracked four times each day on the production line
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Team Daily Plan
Operator 1 Operator 2 Operator 3 Operator 48.00 - 8.308.30 - 9.009.00 - 9.309.30 - 10.0010.00 - 10.3010.30 - 11.0011.00-11.3011.30-12.0012.00 - 12.3012.30 - 1.001,00 - 1.301.30 - 2.002.00 - 2.302.30 - 3.003.00 - 3.303,30 - 4.004.00 - 4.30
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Best Practice – What Does Good Look Like
PROBLEM SOLVING
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Problem Solving – Best Practice
Time
Perf
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Daily incremental problem solving: DMS
Breakthrough problem solving: Rapid Improvement Events
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Define – Measure – Analyse – Improve - ControlBe
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Best Practice – What Does Good Look Like
TEAM WORK
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Teamwork
• Key elements of formal Teamwork to support a lean implementation:• Defined team structure• Defined responsibilities• Shared team objectives• Trained team in lean concepts• Team focus on lean improvements
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Team Work - Skills MatrixBe
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Best Practice – What Does Good Look Like
STANDARD WORK
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Standard Work – Examples Be
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Use of SOP’s in the work placefor all key processes
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Use of One Point Lessons for training staff in key issues
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Good practice – Leader Standard Work
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Summary• The foundational lean practices are applicable to all businesses• It requires leadership from the top and a commitment to stick with it• If you are able to achieve this, you will gain the following benefits:
• Engaged and committed team• Stability of your operations• More time to focus on pro-active improvements• Improved business performance
© Productivity People Ltd 2019
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