LEAN - CONTINUOUS PROCESS IMPROVEMENT
Transforming your organization one process at a time
State of Minnesota - Enterprise Lean
Lean: A rose by any other name
Quality Continuous Process T M
Lean improvement six sigma
Why this? Why now?
? It will help your organization consistently perform at a high level ? It improves employee morale ? It can reduce costs, improve customer satisfaction ? It helps your organization adapt to changes in technology, customer expectations and workforce turnover
What is it?
It’s the 3 Ps
? Purpose – why does the process exist? Do we know what we’re getting, and what we need from the process? ? People – do we have trained people doing the right task, at the right time, in the right way? ? Process improvement – is the process designed and managed to optimize the outputs desired from the process? Is the workplace oriented to maximize the performance of the process?
? Do we need to reduce cycle time? ? Do we need to improve quality? ? Do we need to reduce costs? ? How many widgets per day are we making? ? How do we control and manage variation to reduce errors/defects ? Can we make the same number with less cost
? Do your people know their job? ? Is the work they’re doing value-added? ? Is there a standard work procedure for each step of the process? ? Do we have worker-watchers? ? Are your people physically situated in a way that allows them to efficiently participate in the process?
? Do we periodically take an in-depth review of the current process? ? Do we examine our process for work wasters? (handoffs, waits, rework, multiple reviews, down time?) ? Do we have in-process measures that tell us how well the process is performing?
Basics of Process Improvement
? Involve the people who work in, and are most familiar with, the process ? Establish order through 5S – (sort, straighten, scrub, systematize, standardize) ? Map out the ‘as is’ process, include all steps, waits, handoffs, and review cycles ? Define goals for the improvement effort (e.g. reduce cycle time by 50%, reduce defects [rework] by 50%) ? Create a new process; focus on eliminating work wasters, wait, handoffs, etc.
Sustaining the Improvement
? Document standardized work – insure all employees know and follow the process ? Measure and report on the process outputs ? Keep leadership involved and aware of how the process is performing – is the process continuing to meet the established goals? If not, how will it be addressed? ? Recognize, celebrate and reward the effort and continued performance