Lean Office Lean Enterprise Series
Outline • What is Lean? • 5S & Visual Controls • Kaizen • Value Streams • Pull Manufacturing • Mistake Proofing • Quick Changeover • Six Sigma • Lean Accounting • Theory of Constraints • Human Factors
Eight Service Industry Wastes • Errors in documents • Transport of documents • Doing unnecessary work not requested • Waiting for the next process step • Process of getting approvals • Unnecessary motions • Backlog in work queues • Underutilized employees
Office Process Waste • Examples: • Too many signature levels • Unclear job descriptions • Obsolete databases/files/folders • Purchase Orders not matching quotation • Errors – typo’s, misspelling, wrong data • Waiting – for information, at meetings, etc. • Poor office layout • Unnecessary E-mails
Lean vs. Traditional • Major reduction in sales-order cycle time by 59 percent (from 23 hours to 9 hours) • Engineering change-order cycle time by 91 percent (from two hours to two) • Response time to customer’s quote requests by 83 percent (from 66 hours to 11 hours) • Errors by company employees were reduced by 69 percent • (Tonya, 2004)
Why 5S? • To eliminate the wastes that result from “uncontrolled” processes. • To gain control on equipment, material & inventory placement and position. • Apply Control Techniques to Eliminate Erosion of Improvements. • Standardize Improvements for Maintenance of Critical Process Parameters.
Waste Identification • What waste can be identified in the following photos?
Visual Workplace Implementation • Develop a map identifying the “access ways”(aisles, entrances, walkways etc.) and the “action” areas. • Perform any necessary realignment of walkways, aisles, entrances. • Assign an address to each of the major action areas. • Mark off the walkways, aisles & entrances from the action areas • Apply flow-direction arrows to aisles & walkways • Perform any necessary realignment of action areas. • Mark-off the inventory locations • Mark-off equipment/machine locations • Mark-off storage locations (cabinets, shelves, tables) • Color-code the floors and respective action areas