Lean is an organizational improvement philosophy and set of methods that can be used in any manufacturing or service sector. Our experience leading lean, 5S and kaizen events has shown us that any organization can produce measurable improvement with these simple methods and tools. Lean enables organizations to work more effectively and efficiently by identifying and eliminating waste in processes.
Lean methods vary considerably in function, level of effort, and complexity. They can range from quick fix actions your organization can implement regularly with minimal effort or team participation, to week-long events that require more in-depth planning, participation and a variety of formal tools.
Designed to reduce waste and improve efficiency, Lean methods can be used for a variety of purposes-from making your own working environment less cluttered, think 5S to designing and implementing faster and less complex ways of delivering your customer services.
Let’s take a high level look at the different types of Lean methods we have had success with that can be used effectively.
Simple, Structured Methods for Workplace Improvements
Lean methods, including 5S, standard work, and visual controls, are relatively easy to implement, but provide some defined structure for process improvements. These can be thought of as “daily Lean” methods, since they can be implemented at any time to facilitate continuous improvement, either during or outside Lean events.
For example, the 5S method can help to de-clutter and organize a workspace, making it more efficient. Standard work helps to ensure that improvements are documented and made common practice for process owners . Standardized work answers the 5W+1H of a process – the who, what, when, where, why, and how.
Event-Based Improvement Methods
Several Lean methods are implemented as “improvement events” lasting anywhere from a half-day to five days, or more. Two common types of Lean events are kaizen events and value stream mapping. These team-based methods are very powerful methods for driving improvement in processes. Although the intense period of activity in an event is focused in a few days, keep in mind that events require substantial preparation and follow-up work to be proven successful.
Finding the Method Right for Your Improvement Goals
Before choosing a method, it can be helpful to have a sense of the initial scope of your project so you can more readily identify the method that is best suited for your needs. It is important to match your goals to the function of method, as well as to the level of resources required. Choose a method that is best suited for your problem, and the outcomes you are hoping to achieve.
Question: What type of problem do you have? Answer: I don’t know, what’s a simple method?
Process Walk
A process walk, also referred to as a waste walk, is a rapid technique to help you identify wastes in your everyday operations. A cross-functional team of employees walks through the work area over a short period of time, identifying opportunities to reduce waste and introduce improvements as they progress. Improvements can usually be implemented rapidly, resulting in quick gains. This method can help to engage employees in spotting waste in their day-to-day activities after the initial treasure hunt or process walk.
Typical Duration: A process walk is usually conducted in one day or less.
Identify the employees who are involved with the process. Have the group walk through the workplace with clipboards, while team members write down wastes as they identify them. Some questions to ask during the walk include:
* What inputs and outputs do you see in the process?
* Where do the outputs go?
* What is the typical process time?
* How many items are currently waiting to be processed?
* What causes delays or problems?
* What wastes do you observe, and what causes them?
Looking to implement lean methods and more information on common manufacturing or service environment wastes? Contact us for more details.
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