1 Lean Overview

Introductions  Where were you in 1997? 2

Some Events in 1997  Madeleine Albright became 1 st female Secretary of State  Green Bay Packers won Super Bowl XXXI  The movie Titanic is highest grossing film of all time  Princess Diana died in car crash  UK scientists create “Dolly” the first genetically engineered lamb  EO Executive Order on Quality Improvement 3

Section 1 4

Starfish Story “It sure will make a difference for this one.” 5 Star Fish Story - Making a Difference Every Day

Why Lean? 6 “The best solutions to our problems come from those on the line everyday seeing what works and doesn’t work and how to fix it and how to solve it.” “Lean gives us the opportunity to do more with what we have.” --Governor Gregoire, Lean Symposium 3/24/11 Recently Governor set the expectation that all agencies will have done something with Lean by August 2012.

Where does Lean fit? 7

Section 2 8

Questions  What is Lean?  What are the 5 Lean concepts?  What are the 7 wastes?  What is Kaizen?  What is 5S + Safety 9

What is Lean?  Business management term  Roots in Toyota Production System  A philosophy and tools  Seen in service and government sectors since 1990s 10

One Right Way!? 11

Basic Concepts 12

Define Value Map Value Stream Create Flow Establish Pull Work Toward Perfection Lean Improvement Cycle Improvement Cycle

Seven Wastes 14 7 Wastes Overproduction Waiting Transportation Defects Movement Inventories OverProcessing

Kaizen 15 Kai = Change Zen = Good (for the better) Kaizen = Continuous improvement

Kaizen  “Change for the better”  Continuous improvement  Involves employees  Eliminates wastes 16

Kaizen 17 Day 1 Principles Mapping 5S Kaizen method Day 2 Analysis of current work Brainstorm improvements Day 3 Map new process Try-storm Day 4 Evaluate Standardize Operate Finalize Day 5 Present results Celebrate

Five S Components 18 5 S +Safety Sort Simplify Self-Discipline Standardize Sweep

Sort  Necessary –Used for daily work –Used periodically –I am the source  Unnecessary –Unsafe –Defective –Obsolete –Outdated –Unused –Extra/duplicate 19

Simplify  Easy to see  Easy to locate  Easy to complete 20

Sweep  Clean up  Quickly see what’s missing 21

Standardize  Best practice  Documentation  Communication  Everyone does it 22

Self-Discipline  Good habits  Recognition  Follow up  Celebration 23

Safety  Identify  Investigate  Correct 24

Problem or No Problem? 25

Problem or No Problem? 26

Problem or No Problem? 27

Books Supplies Files Storage areas Sort Arrange Label Organize Simplify Clean surfaces Clean furniture Clean equipment Sweep Processes Changes Communication Agreements Standardize Make 5S a habit Encourage Monitor Celebrate Self- Discipline 5S+Safety Summary 28 Identify Investigate Correct Safety

Implementation 29

Section 5 30

Summary 31