LEAN: Getting Started - Module 1: 8 Wastes & 5S An introduction to Lean tools and methodologies
LEAN: Getting Started • Today’s session will focus on: • 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
LEAN: Getting Started • Why should you care about Lean? • We are experiencing decreased funding • Service demands are changing • State and other organizations are focused on it
LEAN: Getting Started What is Lean? Lean is a systematic approach to identifying and eliminating waste through continuous improvement.
LEAN: Getting Started History of Lean
LEAN: Getting Started There are 6 basic Lean principles - Focus on effectively delivering value to the customer Respect and engage the people that do the work Eliminate waste Maintain flow Pull through the system Strive for perfection
LEAN: Getting Started Most processes contain waste - Wasteis any non-value added activity that slows down or stops the delivery of a service or product provided to the customer.
LEAN: Getting Started Value added activities - • 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
LEAN: Getting Started Non-value added activities (waste) - Any operation or activity that consumes time and/or resources, but does not add value to the service or product provided to the customer.
LEAN: Getting Started The eight (8) wastes - • Defects • Overproduction • Complexity (over-processing) • Waiting • Inventory • Excess Motion • Transportation • Underutilized People
LEAN: Getting Started Let’s start with 5S! Before After Images courtesy of http://kallistaconsulting.com.au
LEAN: Getting Started • The 5S’s - • Sort • Set in order • Shine • Standardize • Sustain Images courtesy of http://www.niftysol.com
LEAN: Getting Started 1S: Sort Distinguish between necessary and unnecessary items and eliminate the unnecessary ones. “When in doubt, move it out!”
LEAN: Getting Started Signs of a disorganizedworkspace - • 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
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.
LEAN: Getting Started Tips for sorting -
LEAN: Getting Started 2S: Set in order “ A place for everything, and everything in its place.”
LEAN: Getting Started Signs of an organized workspace - • 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
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. “Stow as you go!”
LEAN: Getting Started 4S: Standardize • 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.”
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.
LEAN: Getting Started Are you ready to start using Lean?
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) -http://www.wa.gov/esd/1stop/technical_assistance/staff_development.htm • Get involved in a local or regional Lean event • Ask your local administrator about local Lean projects you could get involved in
LEAN: Getting Started Additional Resources - LEAN: Getting Started - Glossary of Terms ESD Office of Lean Transformation website http://insideesd/content/esdpages/lean/lean-home.aspx Results Washington website http://www.results.wa.gov/resources/learnLean/leanWA.asp