Practical Implementation of Lean Practices to Improve

Practical Implementation of Lean Practices to Improve Small / Medium Sized Businesses’ Productivity

Nick Brownsword 21st May 2020

Agenda• Definition of Lean• Two slides of theory!• Practical examples of what lean practices look like

Definition - Lean is not:• A cost cutting programme• A programme to reduce headcount• A project we are working on this year• Only applicable to manufacturing operations• Something that is delegated to the shop floor• A programme run by external consultants• A soft approach with intangible outcomes

Definition - Lean is:• An approach to eliminating all forms of waste within

a business• A philosophy or a way of thinking• A journey that doesn’t end• Led from the top of the organisation• Engages everyone across a business• Develops the skills and capabilities of the team• Creates a work environment where individuals are

willing to give their discretionary effort• Delivers improved business performance

Waste caused by defects or

rejects

Waste caused by unnecessary

movement

Waste caused by inappropriate

processing

Waste caused by waiting

Waste caused by transport

Waste caused by overproduction

Waste caused by unnecessary

Kaizen

Source: Competitive Capabilities International (CCI) TRACC

Best Practices

Leading Change

Teamwork 5S Visual Workplace

Standard Work

Health and Safety

WORLD’S BEST

Problem Solving

Practice – Performance Model

Best Practice – What Does Good Look Like

LEADING AND MANAGING CHANGE

Vision

Daily Activities

Strategy Deployment – connecting teams to the Vision

Leading and Managing Change – Best PracticeBe

A3 Business Plan

HEALTH AND SAFETY

Health and Safety

5S – WORKPLACE ORGANISATION

“Our factory is the best selling tool we have” – Marketing Manager

VISUAL MANGEMENT

Visual Management – Best PracticeBe

Visual Management & ProductivityAre we in

spec?Are we in

Manual Planning and Real Time Tracking

• Daily targets by product• Tracked four times each day on the production line

Team Daily Plan

Operator 1 Operator 2 Operator 3 Operator 48.00 - 8.308.30 - 9.009.00 - 9.309.30 - 10.0010.00 - 10.3010.30 - 11.0011.00-11.3011.30-12.0012.00 - 12.3012.30 - 1.001,00 - 1.301.30 - 2.002.00 - 2.302.30 - 3.003.00 - 3.303,30 - 4.004.00 - 4.30

PROBLEM SOLVING

Problem Solving – Best Practice

Daily incremental problem solving: DMS

Breakthrough problem solving: Rapid Improvement Events

Define – Measure – Analyse – Improve - ControlBe

TEAM WORK

Teamwork

• Key elements of formal Teamwork to support a lean implementation:• Defined team structure• Defined responsibilities• Shared team objectives• Trained team in lean concepts• Team focus on lean improvements

Team Work - Skills MatrixBe

STANDARD WORK

Standard Work – Examples Be

Use of SOP’s in the work placefor all key processes

Use of One Point Lessons for training staff in key issues

Good practice – Leader Standard Work

Summary• The foundational lean practices are applicable to all businesses• It requires leadership from the top and a commitment to stick with it• If you are able to achieve this, you will gain the following benefits:

• Engaged and committed team• Stability of your operations• More time to focus on pro-active improvements• Improved business performance

THANK YOUCall 0800 776 736; Email info@productivitypeople.co.nz

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Practical Implementation of Lean Practices to Improve

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