Lean Implementation Program

Lean is a way of thinking about how you should run your business - it is not a tool. Lean focuses on the customer and what they feel is 'value' . Once this is done and the value and non-value have been identified through the entire 'system' then the next step is to understand how to remove the non-value properly to make your service or production activities flow to the customer. We create a detailed implementation plan which will move you toward a future state and identify the tools required, where and when they are required, who is responsible for applying the tools, and making the transformation from current to future state. Without this plan, companies will make 'point' improvements and likely create what we call 'exciting chaos'. The goal is to improve your bottom line and customer satisfaction by increasing responsiveness to the client/customer, while at the same time, reducing cost and increasing quality.

You can expect to realize immediate results from implementing Lean the 'right way'. We will complete your Future State within 6 months. To accelerate the results, we also have a 3 month Fast Track program.

Goals of the Program

• Complete the transformation of at least one Value Stream.


• Develop the Value Stream Leaders to lead the transformation in other areas.


• Transfer the knowledge by teaching, applying and adapting the concepts simultaneously


• Apply the correct strategy and proper implementation of the tools to maximize success

Lean Assessment

One of the most common questions we are asked is - "Where do we start?" and "How do we do it the 'right' way?" The key to success is to have an effective plan specifically for your situation and environment. Without an effective plan, you will either fail totally or not maximize your potential. We meet with the leadership, discuss the current situation, strategy/direction, and tour your Value Streams. We assess your leadership, staff and operations (office and floor) and then design an effective Implementation Plan/Strategy.

Agenda

• Overview of clients' business


• Critical issues such as crisis or upcoming industry changes


• LEAD Overview: Methods, Style, Expertise, Results


• Walk the entire Value Stream(s) - 'see' the flow


• Discuss activities with appropriate reps from each area


• Discuss - actual Value and Waste


• What you 'saw' - technically and culturally


• What we 'saw' - technically and culturally


• Summarize current state


• What tools are required, application sequence, where they are needed


• Who needs to be involved and when


• Tentative schedule for roll out of the Plan/Strategy

Lean Concepts, Enterprise Value Stream Mapping, Implementation Plan

Introduction To Lean
Provides you with the basic Lean concepts and principles and includes a hands-on waste-finding exercise for the shop or office floor as well as a simulation demonstrating the power of one-piece flow (vs. batch production). Throughout the day, discussions will take place around topics that focus on the participants' situation to demonstrate how Lean works in their environment and how the thinking and tools adapt to their situation.

Enterprise Value Stream Mapping ™
Identify and map Value Streams in both the Current and Future State. This is the most powerful tool in the Lean toolbox for starting your implementation. Our approach to Enterprise Value Stream Mapping ™ combines two approaches - the case study method and a real time shop or office floor mapping. You will be actively involved in applying what you learn as you learn it.

A Future State Map will be created that looks 6 months down the road (3 month program) at what the organization can achieve. The Future State map highlights the waste in the 'system' that can be eliminated or reduced. You will calculate lead-times and compare them to actual processing times. In most cases, the actual processing time is less than 10% of your present lead-time. A 'Future State Implementation Plan' will be developed, which establishes the correct and most effective tools to remove the 'waste' in your system. The Value Stream Leaders will be responsible and accountable for the entire transformation of the end-to-end process from a Current State to a Future State as outlined in the Implementation Plan.

Lean Implementation

The Implementation Plan lays out what the tasks are, when they need to be completed, which tools to use, when to use them, and who is going to be responsible for them. Without an implementation plan, companies will fall into the trap of completing 'point improvements' and is one of the major reasons for companies failing to reach their full potential.

Cultural
The people and culture of your team or organization define the 'system' as much as procedures/processes. As a leader, you need to make changes to the culture and behaviors of your team. You must tie these changes closely to your business goals - cultural change needs defined measures of success such as improved speed, efficiency and success in reaching your Future State. The work on the people side of change is essential to the long-term viability of a Lean enterprise. Building multi-level buy-in and shared responsibility for implementing your future state is critical to creating your Lean enterprise.

The objective is to build Lean Implementation skills for leaders and teams in an interactive learning environment where tools/techniques can be practiced. Hands-on practice approach with key tools for building successful teams: creating ownership, responsibility, accountability; creating and sustaining behaviors and culture; dealing with resistance and conflict; mentoring change agents; setting expectations and measuring results.

Implementation

• Five 3-day Implementation Support and Training Sessions


• Future State transformation in 5 to 8 months (4 to 6 weeks between Sessions)

Four Technical Sessions
Each session consists of 3 days of Training, Implementation and Support with a defined action plan, with defined results and purpose as dictated by the Implementation Plan. This could be a Kaizen event (a focused continuous improvement activity), learning new tools moving the group to another level of implementation or a combination of all of these.

One Cultural Session – Creating a Lean Culture
The Creating a Lean Culture session will assist the client in building and enhancing the Lean Implementation skills for leaders and team members in an interactive learning environment. Tools and techniques will be practiced and a personal Lean participation plan will result.

The approach will include hands-on practice along with key tools for building successful Lean Implementation teams: creating ownership, responsibility and accountability; creating and sustaining Lean behaviors and culture; dealing with resistance and conflict; mentoring change agents; setting expectations and measuring results.