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Lean Six Sigma toolkit with KanBan?

Kanban Definition, very usefull Lean Tool

  • A communication system used to signal starting work on the work items in processes – Kanban is Japanese for card or signal

Concept

  • The Kanban signal contains the specific information required to authorise the commencement of work and comes from the next step in the process; without the signal, no work is started

This means that the customer pulls the item through the entire value chain

Nothing is supplied until it is needed by the next process step (JIT)

This means all the links in the value chain have to be very, very close

Examples of Kanban mechanisms

  • Cards, faxes
  • Bins
  • Defined Floor Location
  • Call Light
  • Electronic Signal (email, EDI, RF, Bar Code Reader)
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Lean Transformation and the Art of War.

The success of any Lean Transformation depends on a few key factors.

 

In the “Art of War” of Sun Tzu, one can define 3 factors that will determine the outcome of a battle:

  • If you know the enemy and know yourself, you need not fear a hundred battles.
  • If you know yourself but not the enemy, for every victory gained you will also suffer a defeat.
  • If you know neither the enemy nor yourself, you will succumb in every battle.

 

what is needed to win a battle? What is the profit to be delivered from the process? VOB

Sun Tzu’s three conditions helps determine the success of a business:

If you understand the needs of your customers, What is the customer experience to be delivered? VOC

If you know the capabilities  of your own business but do not understand the needs of your customers or the strengths of your competitors, for every increase in sales revenue you will reduce profits and lose market share. VOP

If you do not know the needs of your customers, the strengths of your competitors nor the capabilities  of your own business, you will succumb to market forces and eventually lose everything.

The process for creating a high performance organization must start with a business knowing the limits of its own capabilities . The company must define and understand its current state before it can develop a plan to determine where it must improve its processes to create a future state. However, defining the future state cannot happen until the business understands the needs of its customers and the strengths of its competitors. Once a business has clearly defined these 3 factors it can develop a future state that serves its customer and is in a stronger position to compete in the market place. One way to do this effectively is to follow the “10 Steps to become a Lean Enterprise” model.

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Lean Six Sigma applies Takt Time and Line Balancing

Takt Time is the principle that all activity within a business is synchronised by a “drum beat”, set by the customer demand. This brings ‘calendar time’ into the equation.
Notice how neatly Takt time links with line balancing. You set the capacity of each process step to the demand of the customer.

Linking the internal value adding system directly to the customer may seem difficult but is necessary to allow the customer to pull value from the value adding system.

Each process link working in isolation at full speed will cause a mismatch between links. Some areas over-produce, some cannot keep up…

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Lean Six Sigma implementation have a first look at the Traditional Layouts

During your Lean Six Sigma implementation, have a first look at the Traditional Layoutsof the area, which are often complex and bottlenecks affect the flow of materials, information and value adding capability. Common disadvantages are

•Complex flows of material.
•Reduced vision and ownership of the
•Total value chain.
•Operators concentrate on islands of efficiency.

Better try out Cell Layouts, which are typically U shaped, operations are combined and single piece flow is adopted. Bottlenecks are eliminated by the use of multiple operators or machines. Immediate advantages are usually

•The flow of materials becomes smoother.
•There is no queuing between machines.
•Throughput time is reduced.
•Operators are trained in more than one task.
•Value stream visibility is much high.
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Lean for Production and Services

A popular misconception is that lean is suited only for manufacturing. Not true. Lean applies in every business and every process. It is not a tactic or a cost reduction program, but a way of thinking and acting for an entire organization.

The core idea is to maximize customer value while minimizing waste. Simply, lean means creating more value for customers with fewer resources.

A lean organization understands customer value and focuses its key processes to continuously increase it. The ultimate goal is to provide perfect value to the customer through a perfect value creation process that has zero waste.

To accomplish this, lean thinking changes the focus of management from optimizing separate technologies, assets, and vertical departments to optimizing the flow of products and services through entire value streams that flow horizontally across technologies, assets, and departments to customers.

Eliminating waste along entire value streams, instead of at isolated points, creates processes that need less human effort, less space, less capital, and less time to make products and services at far less costs and with much fewer defects, compared with traditional business systems. Companies are able to respond to changing customer desires with high variety, high quality, low cost, and with very fast throughput times. Also, information management becomes much simpler and more accurate.

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The word is, lean transformation !

Businesses in all industries and services, including healthcare and governments, are using lean principles as the way they think and do. Many organizations choose not to use the word lean, but to label what they do as their own system, such as the Toyota Production System or the Danaher Business System. Why? To drive home the point that lean is not a program or short term cost reduction program, but the way the company operates. The word transformation or lean transformation is often used to characterize a company moving from an old way of thinking to lean thinking. It requires a complete transformation on how a company conducts business. This takes a long-term perspective and perseverance. A client of PEEC doing just that, it’s the new word! lean transformation.

Lean for Production and Services A popular misconception is that lean is suited only for manufacturing. Not true. Lean applies in every business and every process. It is not a tactic or a cost reduction program, but a way of thinking and acting for an entire organization.

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Looking for new types of waste in Lean

As Lean concepts have been developed over the years some other wastes have been added to the original 7 (TIM WOOD).

  • The waste of Untapped Human Potential

This relates to intellectual capacity not just physical labour

 

  • The waste of Inappropriate Control Systems

This relates to minimising complexity (Push ERP/MRP/SAP vs Pull JIT and Kanban)

 

  • Wasted Energy and Water
  • Waste of Customer Time and Defecting Customers
  • Service and Office Wastes

 

  • The waste of Human Capacity

This relates to physical capacity during meetings, decision making

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Don’t get stuck in ‘methodology wars’

It is easy to get stuck in deciding what methodology to use.

Yet the underlying activities are very similar.

The real work is in using the DMAIC methodology and LSS Black belts should always be able to use any sensible methodology;

  • If you try to make improvements or solve problems without a methodology, you will probably jump to conclusions or you may become lost.
  • All improvement methodologies cover the same basic sequence of events, see also PDCA
  • Methodologies designed to react to new problems, such as DMAIC, include containment actions to quickly stop the customer being affected.
  • Use the Lean Six Sigma methodology, it will lead to innovation.
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How to choose a good Lean Six Sigma project.

Selecting and defining an Improvement project:
3 key questions

Question 1 – What is the problem that needs to be fixed?

What must be improved? (not how to improve it). Clear focus on the issue that is to be changed (not the solution).

Question 2 – Why is it important?

Why are you going to spend time and effort to improve the situation? Clear focus on the importance of this project.

Question 3 – How will I know when I have succeeded?

What can I measure that will show me I have finished the project? This measure should be a measure of ‘quality’, ‘waste’, ‘on-time’, ‘Euros’ or ‘customer satisfaction’. Clear focus on the ‘measurable benefits’.

Defining the problem, is the first step to take…
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Change Management in multinational organisations is a critical success factor for the lean implementation

Intercultural Management.

We are all product of our environment in which we grew up and in which we make a daily living. In some cases, the way we see the world, or the way in which we make decisions is not the same as perceived in other cultures or countries.

For example, did you know that during a meeting with French managers hardly any decisions are made? For an English businessman, this may sound strange as the entire purpose of a meeting is getting actions ‘ticked off’…

If you were counting on a private meeting, a ‘one-on-one’, with a manager in Poland, don’t be surprised if at least 5 others will show up!

Although these are generalizations, I have been in situations where exactly these kind of misunderstandings led to frustration and threatened to become an inhibitor to communication.

Fortunately, this is not necessary by anticipating what can be expected when dealing with other countries and cultures.

Basic Concepts

A well-known study performed at IBM during the 70’s by Geert Hofstede over 70 countries yielded the so-called Cultural Dimensions that characterize each country and culture.

It is still used as a foundation to work with when studying the ways of management, communication, decision making and styles.

Cultural Dimensions

(Geert Hofstede)

Below the cultural dimensions with some examples. (Full overviews can be found by searching on-line for Geert Hofstede.)

Power Distance Index – PDI

To what extent do the members of the organization who have less power accept that power is unequally distributed?

Austria, Denmark —
India ++

Individualism – IDV

This is the level of integration of the individual into groups. Does the society (or organization) consist of individuals or is it a coherent group? High score indicates high level of individualism.

Netherlands, UK ++
China —

Masculinity – MAS

Masculinity versus Feminity indicates how different roles are distributed amongst men and women.

Masculinity can be associated with the level of assertiveness and competitiveness while Feminity represents values like caring for others.

Arab countries ++
Netherlands, Norway —

Uncertainty Avoidance Index – UAI

A measure to which extent uncertainty and ambiguity are tolerated in society. Can also be interpreted as to which extent the Truth is felt to be important in society. When the Truth is felt to be really important, we can expect strong laws, avoidance of insecurity or unusual situations, security measures and a relatively low tolerance for different opinions.

Belgium, Portugal ++

Long-Term Orientation – LTO

Principal values associated with Long-term are perseverance, thrift, while Short-term orientation can be recognized by respect for tradition, not losing face.

China ++
USA —

Having lived and worked for longer periods of time in other countries, I know that these type of categorizations can be ‘a bit dangerous’ when radically applied in daily situations. However, a large number of additional studies have been performed to refine and make practical use of the work of Mr. Hofstede that have helped cross borders for many business people operating globally.

 

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