Presented by B rons & S ilva

What is Lean? “Lean is a customer-centric methodology used to continuously improve any process through the elimination of waste in everything you do” It is based on the ideas of “Continuous Incremental Improvement” and “Respect for People.”

The Basic Principles of Lean are… Pursuing perfection Mapping the value stream Responding to customer pull Creating flow by eliminating waste Identifying customers and specifying value

Mapping the Value Stream Is walking through a process and documenting every step This process helps identify the customer value This process helps identify non-value activities

An In-House Example of Mapping out the Value Stream Paul wants to advertise in a local paper about a cool new program at COTR Paul Prints the Ad Req Paul goes into SharePoint and fills out an Ad Req The Marketing department prints two copies Paul takes the Ad Req to his Manager for a signature Paul's Manager signs the Ad Req Paul walks to printer and scans the document to his Paul sends the to the Marketing department Marketing keeps one to work with Marketing sends one to Kristy * In-House Advertising Requisition (Ad Req) Process Black Press Invoice Process Black Press invoice comes in mail to COTR The mail is sorted in the COTR Mailroom The invoice travels to COTR Finance dept. The mail is sorted in Finance A/P Clerk date stamps the invoice The invoice is sent back through interoffice mail The mail is sorted in the Mailroom The invoice travels to Kristy Kristy’s Process When she Receives Both Documents Print an online copy of the Ad Log on to the Black Press website Pair the three documents Place one copy into interoffice mail File a copy in Kristy’s office The mail is sorted in the COTR Mailroom The documents travel to COTR Finance dept. The mail is sorted in Finance Photocopy the documents A/P Clerk prepares cheque for Black Press to pay invoice This Process could take anywhere from one hour to multiple days depending on schedules etc. This process could take up to 3 days depending when invoice is received, when mail is sorted, schedules etc. This process could potentially take up to 3 days depending on printer access, mail pick up, workload etc. Paul s completed form to Marketing and CC’s his supervisor for approval and Kristy for invoicing purposes Sign up for paperless billing with Black Press and the online Invoice

How do you Define Value? Your customer defines value or value-added by following these conditions: It must transform the product or service. The customer must be willing to “pay” for it. It must be done correctly the first time If you don’t meet all three criteria, you have non-value- added activities or waste

The Seven Forms of Waste Transportation: no signs identifying rooms or departments – third story wing Waiting: waiting for approvals or signatures, attendees not on time for meetings Overproduction: Producing reports that no one needs or reads Defects Data entry errors, invoice errors Inventory Excessive office supplies or materials, things can become stale or outdated Movement Having a printer located far from your office or work station Extra Processing Reentering data from a paper based source

Two Additional Forms of Waste Untapped human potential Talent that is unknown or not used in the work environment Interruptions Perhaps some interruptions could be avoided if we properly orient staff to new processes and to find resources and materials, rather than have one person hold all of the knowledge

Let’s Build a LEAN Brick House!

Station 1 (foundation & second floor) Materials: 4 eight pin blocks Instructions: Stack blocks width and lengthwise to make a strong foundation for your house Transfer to Station 2

Station 2 (third floor) Materials: 2 eight pin blocks and the assembled piece from Station 1 Instructions: Stack the two eight pin blocks on the top of the assembled piece from Station 1, opposite direction of the foundation. Creating a three tiered block Transfer to Station 3

Station 3 (roof and chimney) Materials: 2 four pin sloped roofs, one chimney and the assembled house from Station 2 Instructions: Add the sloped sections facing outwards for rain drainage Attach the chimney to the top Transfer to Station 4

Station 4 (Inspection and Recording) Materials: The completed house from Station 3 Instructions: Ensure the foundation and third story bricks are stacked in the same direction (cracks align on these floors) Ensure the roof and chimney are securely attached Record the completed houses and note any defects Transfer to Station 5

Station 5 (Demolition Team) Materials: Completed house from Station 4 Instructions: Disassemble the house Return the blocks to the appropriate supply container – NO RUNNING!

Person 6 (Supply Transporter) You are responsible for supplying each Station with the appropriate materials: Station eight pin blocks Station 2 – 2 eight pin blocks Station four pin slanted roofs and one chimney

Stipulations: Walk to the next station – no passing across the table and work stations cannot be moved.

End of Round One Tally the materials that are at each workstation Count individual pieces of material that are in production line including pieces used in partially built houses. The supply that is in the bin is not counted.

Eliminate transportation and movement waste Stipulations: Each person has to keep the same job

End of Round Two Tally the materials that are at each workstation Count individual pieces of material that are in production line including pieces used in partially built houses. The supply that is in the bin is not counted.

Eliminate over-production, inventory, and waiting waste Stipulation: Each station is allowed one part in transit and one on their workbench

End of Round Three Tally the materials that are at each workstation Count individual pieces of material that are in production line including pieces used in partially built houses. The supply that is in the bin is not counted.

Conclusion Can you think of areas in your job or personal life where you could use a process map to identify waste and eliminate non-value added time/resources?

Sources Adams, Bob, Lean 101 Training, February 26, 2016 Sayer, Natalie J. and Williams, Bruce, Lean for Dummies, April to/content/lean-for-dummies-cheat-sheet.htmlhttp:// to/content/lean-for-dummies-cheat-sheet.html Wormack, James P. and Jones, Daniel T. Lean Thinking, New York: Free Press, Print