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LEAN: Getting Started - Module 1: 8 Wastes & 5S An introduction to Lean tools and methodologies.

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Presentation on theme: "LEAN: Getting Started - Module 1: 8 Wastes & 5S An introduction to Lean tools and methodologies."— Presentation transcript:

1 LEAN: Getting Started - Module 1: 8 Wastes & 5S An introduction to Lean tools and methodologies

2 LEAN: Getting Started A brief history on Lean Two key Lean concepts – 8 wastes and 5S process Activities to practice Lean concepts Tips on how to get started using Lean Q&A with Lean experts Today’s session will focus on: 2

3 LEAN: Getting Started We are experiencing decreased funding Service demands are changing State and other organizations are focused on it Why should you care about Lean? 3

4 LEAN: Getting Started What is Lean? Lean is a systematic approach to identifying and eliminating waste through continuous improvement. 4

5 LEAN: Getting Started Early 20 th Century Time & motion studies, industrial psychology Mid 20 th Century Training Within Industry (TWI) Late 20 th Century Lean Manufacturing 21 st Century Lean Office History of Lean 5

6 LEAN: Getting Started There are 6 basic Lean principles - 1.Focus on effectively delivering value to the customer 2.Respect and engage the people that do the work 3.Eliminate waste 4.Maintain flow 5.Pull through the system 6.Strive for perfection 6

7 LEAN: Getting Started Most processes contain waste - Waste is any non-value added activity that slows down or stops the delivery of a service or product provided to the customer. 7

8 LEAN: Getting Started An activity is “value added” if, and only if, these three conditions are met: The customer would be willing to “pay” for the service or product The “form, fit, or function” of the service or product changes overtime to keep it relevant and valuable The service or product is quality Value added activities - 8

9 LEAN: Getting Started Non-value added activities (waste) - 9 Any operation or activity that consumes time and/or resources, but does not add value to the service or product provided to the customer.

10 LEAN: Getting Started The eight (8) wastes Defects 2.Overproduction 3.Complexity (over-processing) 4.Waiting 5.Inventory 6.Excess Motion 7.Transportation 8.Underutilized People

11 LEAN: Getting Started Type of Waste Examples Defects Data errors, missing information, document errors, confusing instructions or requirements, typos Overproduction Unneeded reports and copies, excess messages, doing work not requested ComplexityUnnecessary process steps, too many signature levels, workarounds Waiting Time for approval cycles, waiting for information or decisions, waiting for people in meetings Inventory Excess materials/information, obsolete databases/files/folders, unused reports Excess Motion Trips to the printer and copier, unnecessary movement to find files or supplies, travel to meetings, multiple “clicks” to access electronic information TransportationReport routing, transport of documents, document storage Underutilized People Underutilizing people’s knowledge and creativity, uneven workflow resulting in some team members overburdened while others are underutilized 11

12 LEAN: Getting Started Let’s start with 5S! Before After 12 Images courtesy of

13 LEAN: Getting Started The 5S’s - Sort Set in order Shine Standardize Sustain 13 Images courtesy of

14 LEAN: Getting Started 1S: Sort Distinguish between necessary and unnecessary items and eliminate the unnecessary ones. “When in doubt, move it out!” 14

15 LEAN: Getting Started Key documents, items or information can’t be located quickly or at all Large quantities of the same supplies are stored in multiple locations Areas, drawers and cabinets are “dumping grounds” for miscellaneous items Supply areas contain items that have not been used in years, like toner cartages for printers that have been surplused, cords and cables to unknown electronics 15

16 LEAN: Getting Started How to sort things: Decide what you need to do your work. Remove unnecessary clutter. Throw away all trash and unrelated materials in the workplace. Classify and store all tools and materials. Remove items that are broken, unusable or infrequently used. 16

17 LEAN: Getting Started Tips for sorting - 17 PriorityFrequency of UseSort Action High Once per dayLocate at the workplace Medium Once per month Store together Once per week Low Once per year Store away from the workplace Less than once per yearThrow away/surplus

18 LEAN: Getting Started 2S: Set in order “ A place for everything, and everything in its place.” 18

19 LEAN: Getting Started Office appearance is neat and clean with minimal clutter Needed items are quickly and easily located You can immediate spot out-of-place items or excessive or insufficient inventory 19

20 LEAN: Getting Started 3S: Shine Identify inconsistencies, problems and improvement opportunities. Remember to include electronic files. At the end of the day, tidy the work area and be sure everything is restored to its place. 20 “Stow as you go!”

21 LEAN: Getting Started 4S: Standardize 21 In groups, establish standards, guidelines and schedules - make them visual. Continue to assess the use and disposal of items. See and recognize what needs to be done. “If you can’t see, you don’t know. If you don’t know, you can’t control.”

22 LEAN: Getting Started 5S : Sustain Maintain and review new standards. Sustain 5S focus to prevent falling back into to old habits. Conduct regular walk-throughs and inspections. Continuously look for ways to improve. 22

23 LEAN: Getting Started Are you ready to start using Lean? 23

24 24 LEAN: Getting Started What’s next? Start practicing your new skills Sign up for Lean: Getting Started Module 2 – Standard Work and Visual Controls (January 2014) - Get involved in a local or regional Lean event Ask your local administrator about local Lean projects you could get involved in

25 25 LEAN: Getting Started Additional Resources - LEAN: Getting Started - Glossary of Terms ESD Office of Lean Transformation website Results Washington website

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