EasyProblemSolving
Lean
A waste elimination method
What is Lean ?
A principle driven, tool based philosophy that focuses on eliminating waste so that all activities/steps add value from the customers perspective.
Its all about continuous waste elimination
What is waste?
Waste, in lean thinking, is defined as all activities that do not add value from a customer's perspective and that can be removed
What is Value?
An activity is a value-adding activity - if it enhances the product or service from the customer perspective
Ask :
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Will you be willing to pay this activity as a customer - if not its a waste
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Is any change or transformation happening in the product - if not its a waste
Measure: Measure the Y & Xs
1. Eliminate Waste
2. Minimize inventory : produce only when needed
3. Maximize flow : of the production line
4. Pull from demand : produce when their is demand
5. Meet customer requirements
6. Do it right the first time
7. Empower workers
8. Ban local optimization : complete process/ chain needs to be optimized
9. Partner with suppliers
10. Create culture of continuous improvement
The 8 Lean wastes - "TOM D WIPS"
1. Transportation
Inefficient transportation; unnecessary movement of parts / files / equipment without creating value
Example technique : reduce inventory, approvals
2. Over Production
Production more than required or before time causes waste
Example technique : Kanban (signal to produce upstream)
3. Motion
Unnecessary human movement. Walking to & from copier , bending down to pour water, too many clicks on a site
Example technique : 5S, human-centric design
4. Defects
The produced work has defects ; too much checking for errors or rework
Example technique : Poke-yoke ( mistake proofing)
5. Waiting
Waiting for previous step to complete work, so that you can do your work
Example technique : eliminate hand-offs
6. Inventory
Keeping extra items / persons. Bench staff, too many items in storage, warehouse
Example technique : Kanban
7. Processing
extra/over processing refers unnecessary value adding steps in the process
Example technique : ECRS
8. Skills
Underutilized skills, talent - Limited employee authority and responsibility
Example technique : Cross - Training