«Visual Lean» service overview –IT-solution for monitoring

the development of production system based on Lean

IT-SOLUTIONIN LEAN

Innovative CompanyThe company is founded by a group of experts - supporters of Lean philosophy to develop IT-solutions.

2012October

Nizhny Novgorod IT-park residentsSuccessfully passed the regional innovative projects selection and opened the first office in Nizhny Novgorod.

2012November

IT-SOLUTION IN LEAN LEANSOFT HISTORY

Version 2.0 of Visual LeanDevelopment of new functional features. Development of new services in the field of Lean manufacturing.

2014January

Visual Lean LaunchVersion 1.0 of Visual Lean web-service in Russia. The first pilot projects are launched.

2013May

2013 November

Kazan IT-park residentsSuccessfully passed the regional

innovative projects selection. Opened the office in Naberezhnye Chelny.

PartnershipEstablished collaboration with Kaizen Institute and

Lean Center “Prioritet” 2014April

International contestThe company has become the general

partner and the organizer of the international competition

"For leadership in Lean - 2014"

2014January

2014February

Key customers

2015June

Project “Visual Lean” is winner of the contest “IT-Volga” by Skolkovo Foundation

2014September

Technopark “Skolkovo” residentsLeanSoft became resident of Technopark “Skolkovo”.

2015 -2016

Key customers

Version 3.0 of Visual Lean

Development of new functional features. Development of new services in the field of Lean manufacturing.

2016September

• How to improve employee engagement in continuous improvement process?

• How to monitor every department on Lean conformance in a quality and timely manner?

MAIN ISSUES IN IMPLEMENTING LEAN

• How to reduce wastes performing Lean audits on a regular basis at all the departments of the company?

• How to draw attention of personnel to the gaps in their knowledge of Lean and encourage them to educate themselves in this area?

®

PROBLEMS SOLUTION

Audit Tracking System

SOLUTION IS IN USING OF SPECIALIZED INTERNET-SERVICE

The «Visual Lean» service facilitates the work of auditors and automates monitoring of improvements in Lean towards perfection.

«VISUAL LEAN» SERVICE DESCRIPTION

• Carrying out weekly internal audits in the area of Lean manufacturing at all the departments of the company;

• Generating the Waterfall charts using the results of every passed audit;• Generating trends showing the level of implementation of Lean philosophy, principles and

tools at all the departments in real time;• Generating and printing reports online;• Tracking the audits status (how many planned audits have already been conducted at the

moment)• Performing cross-check audits to identify incorrect information• Providing support information on all the questions of a checklist

Main functions of the «Visual Lean» service

PROCESS OF PRODUCTION SYSTEM IMPROVEMENT USING «VISUAL LEAN»

Analyze the audit results and trends in the servicePrepare the weekly plan for

improvementsWork on improvementsCarrying out all audits in the service

Creation of the enterprise structure and users in the

«Visual Lean» service

weekly

HOW TO START USING «VISUAL LEAN» SERVICE

1. Create a profile and the structure of the company, which will be used for monitoring of production system development.

2. Create «Visual Lean» users and add their personal details.

3. Assign users to the departments and define their roles in the «Visual Lean» (Manager, Auditor, Trusted Auditor)

To start an assessment using the IT- service «Visual Lean», it is necessary to perform the following actions:

Компания

Division №1 Division №2 Plant/shop №1 Plant/shop №2

Tree

leav

esTr

ee n

odes

Departments

To start using the «Visual Lean» service, it is necessary to create the structure of the company in the form of a tree, where: • Tree root is an enterprise or company• Tree nodes are companies, divisions, plants, shops, etc. The assessment of tree

nodes is based on the assessment of tree leaves. • Tree leaves are the departments to be assessed. Assessment is performed only at these

departments.This structure will be used in the course of the assessment and calculation of results.

SET MONITORING COMPANY STRUCTURETr

ee ro

ot

Enterprise/company

Departments Departments Departments

FIRST NAMELAST NAMEPHONEEMAIL

ADDING USERS

FIRST NAMELAST NAMEPHONEEMAIL

FIRST NAMELAST NAMEPHONEEMAIL

User accounts must be created for all users of the «Visual Lean» service who are going to use it for monitoring of the production system development.

AuditorsManagers Trusted Auditors

Tree

root

Manager Manager Manager Manager

Tree

leav

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ee n

odes

USERS AND USERS’ ROLES ASSIGNMENT

ManagerTrusted auditor

Auditors Auditors Auditors Auditors

To use the service, it is necessary to assign users with clearly defined roles for every department in the company structure. Roles available: 1. Auditor – fills in the checklists;2. Manager – analyses visualized audit results and reports;3. Trusted auditor – conducts an expert assessment of the

departments with significant deviations.

AUDITORSConduct weekly internal audits on their departments

TRUSTED AUDITORSConduct an expert assessment of the departments with significant deviations

LEAN PHILOSOPHY3 CHECKLISTS

LEAN TOOLS12 CHECKLISTS

LEAN PRINCIPLES4 CHECKLISTS

HOW AUDITORS WORK

Lean Philosophy ( 3 checklists )• Meeting the material needs of a person;• Meeting the professional needs of a person;• System of management and control based on Lean philosophy.

Lean Tools ( 12 checklists )• Total productive maintenance (ТРМ); Single-Minute Exchange of Die (SMED);• Value stream mapping (VSM); Production smoothing (Heijunka);• Standardization; Built in Quality; Wastes analysis; “5S” System;• Andon system; Kaizen; Kanban; Visualisation.

Lean Principles ( 4 checklists ) based on 14 principles of The Toyota Way• Long-Term Philosophy;• The Right Process Will Produce the Right Results;• Add Value to the Organization by Developing Your People;• Continuously Solving Root Problems Drives Organizational Learning.

LIST OF CHECKLISTS

YES

“YES” answer is put, if the described

requirement is being fully executed.

“NO” answer is put, if described requirement is not being executed at all or partially executed, or the respondent does not understand

what is being asked about.

All the questions in checklists are divided into two types:• “Yes-No” questions. The number of such questions amounts to 85% of all.• “Open” questions. It is necessary to point the number of work places that meet certain criteria.Such questions allow to reduce the influence of human factor when conducting an assessment.

TYPES OF QUESTIONS IN THE CHECKLISTS

NO

Data from all checklists of every department should be input to the service once a week. Upon completion of the assessment, the IT-service calculates the results automatically, introduces appropriate amendments to the scores for companies, divisions, plants, departments and so on and generates a ranking. All the findings instantly become available for the management of any level depending on access right.

Start new audit and download the blank

checklist

Answer the questions in the checklist

Enter answers into internet

service

Complete audit and get results (rating, charts,

reports)

INTERNAL AUDIT PROCEDURE

Line chart

Bar chart

Radar chart

Pie chart

Waterfall chart

GRAPHIC TRENDS (Line charts)Provide visual information about the development of the company’s production system based on philosophy, principles and tools of Lean production.

DIAGRAMS AND CHARTSAllows to get a visual information about:• Level of implementation of the

philosophy, principles and tools of lean manufacturing,

• Bottlenecks identified using various Lean criteria.

DATA VISUALISATION

TYPES OF MANAGER’S REPORTS«Visual Lean» service automatically generates reports for selected departments about the results of passed audits for a selected time period

• REPORT ON AUDIT RESULTS FOR A SELECTED DEPARTMENT GROUPED BY CHECKLISTSContains assessment results for every checklist only for a selected department with an indication of the percentage of passed audits. The results are grouped by checklist.

• REPORT ON AUDIT RESULTS FOR A SELECTED DIVISION/PLANT/SHOP GROUPED BY LEAN AREASContains assessment results for all passed in a selected division audits. The report includes the names of departments in division and results for every department. The results are grouped by Lean areas: Philosophy, Tools, Principles.

• REPORT ON PASSED AUDITS FOR SELECTED DIVISION/PLANT/SHOP/DEPARTMENT IN TABLE VIEWContains assessment results, which are displayed in the table. Results are displayed for every department for every checklist with an indication of persons who are responsible for audit on every department.

FIND PROBLEM

Based on the results of passed audits

employees find bottlenecks and put

them into the online-Service.

ASSIGN EXECUTOR

Assign the problem to any employee-user

who will be responsible for its

resolution.

TRACK STATUS (CHANGES)

Track the resolution status of found problems, e-communicate with executers and make

necessary changes into the online-service.

IMPLEMENT SOLUTION

Close problems, when they were resolved and

solutions were standardized in the

company.

PROBLEMS TRACKING

QUALITY MORALECOSTDELIVERYSAFETY

S Q D C M

IDENTIFYING PROBLEMS BY CATEGORIES

INFOGRAPHICSGRAPHIC TRENDS

CHARTS TABLES

Dashboard displays the key data for every department or group of departments or across the enterprise. Any manager can quickly find the information, indicators, results he needs.

DASHBOARD

KEY CUSTOMERS

5 REGIONS

24COMPANIES

33552AUDITS

11CITIES

ORGANIZERInternational Public Organization for Development of Production Systems Based on Lean Principles and Philosophy

«FOR LEADERSHIP IN LEAN - 2014»INTERNATIONAL COMPETITION

GENERAL PARTNERLeanSoft Company

«Visual Lean» Service was used by the contest organizers as the main platform for evaluation of production system development of the participating companies based on Lean principles and tools.

ORGANIZING INTERNAL COMPETITIONSKAMAZ GROUP COMPETITION «PSK LEADER»

«Visual Lean» Service was used by the competition organizers as the main platform for evaluation of production system development of the KAMAZ group divisions based on Lean principles and tools.

ORGANIZERKAMAZ Production System Development Committee

ADVANTAGES OF USING «VISUAL LEAN»• Ready-made, single for the entire team

method of estimation and calculation of results, based on measurable indicators;

• Common Information Space;• Automatic calculation of results and online

current rating of participants;• Accessibility, transparency and visualization of

results;• Staff Involvement in the process of

continuous improvement through participation in an internal competition using «Visual Lean» service.

PROJECT DURATION 8 months

NUMBER OF COMPANIES

22 companies

NUMBER OF DEPARTMENTS

932 items

NUMBER OF USERS

1054 persons

EXPERIENCE OF IMPLEMENTATION - KAMAZ

INVOLVED STAFF21 000 employees

PASSEDAUDITS

97830 items

PROCESSED USERS REQUESTS458 items

AVERAGE LEAD TIME PER REQUEST

1 day

EXPERIENCE OF IMPLEMENTATION - KAMAZ

LEAN PHILOSOPHY

+10%

LEANTOOLS

+9%

LEANPRINCIPLES

+12%

GROWTH INDICATORS BY AREASFOR 5 MONTHS*

*according to “Lean Manufacturing. Winners Technologies.” magazine. Issued by KAMAZ. Issue №2, April 2016.

To optimize costs of input control and be sure in delivery quality, a customer should help to develop production systems of its suppliers based on Lean methods and tools.

SUPPLIERS DEVELOPMENT

To establish trusting relationships with suppliers, a customer may ask them to regularly self-assess their production system and share the results.

It is possible to do it using «Visual Lean» service.

The customer will see the development of the suppliers’ production systems and any issues identified in real time and will be able to help the suppliers address them on time. Using this service the customer will be able to highlight any deviations, which the supplier needs to eliminate.

Kaizen Tracking System

Service helps to record, control and track the status on implementation of Kaizen suggestions and Kaizen projects. “Kaizen” serves to involve personnel into the CIP process, accumulate the common company-wide expertise base, and replicate successful experience. Employees can enter data on their Kaizen suggestions and their application in practice into the system. Both effective improvements and improvements, which didn’t give a positive result, are sent to the expertise base and stored in the system.

Common expertise base helps the employees, who are located remotely from one another, to share openly and adopt experience, apply already proven effective improvements and refrain from testing the improvements, which weren’t effective on the other areas. All the data in the expertise base are systematized enabling quick retrieval of data and saving much time and resources due to the two-way communication between the key players on any Kaizen suggestion put into the system.

SOFTWARE UNDER DEVELOPMENT

Standard Operating Procedure

Specialized terminal with pre-installed IT-solution enables automation of the input and output of standard operating procedures (operating instructions) and leveling with the help of Yamazumi chart. The software will significantly speed up the document flow, allowing all the users to be aware of all the changes online. It is an automated and multipurpose system where you can create, record, store, or get approvals of electronic manuals. This system will help to increase labor productivity of manufacturing engineers and workers by reducing the time necessary for documents development, amendment and approval.

• Fast creation, editing and agreement of SOP• Automatic synchronization between the charts when making amendments• Quick creation of spaghetti chart• Quick filling in of visual safety guidance • Simple adding and editing of graphic image of operation• Storage of revision history in SOP, quick search and sorting• Informing the stakeholders online about changes in SOP

Main Service functions

Interactive Learninig System

The service is designed for staff training on Lean production.

Knowledge base contains: glossary of terms, descriptions of theoretical and practical skills for application of methods and tools of Lean production, step-by-step guide on addressing the problems identified.

This service will make it possible to certify personnel for knowledge of Lean and create employee training and refresher training programs.

The service will allow creating teams inside a company, engaging suppliers and training them online.

Service will allow to either conduct training inside the company for own personnel or engage suppliers and train them online.

info@lean-soft.ru

www.lean-soft.ruvisuallean.ru

@lean_soft

Naberezhnye Chelny, Mashinostroitelnaya, 91IT-PARK+7 (8314) 144-844

Nizhny NovgorodRodionova street, 192 D ,+7 (8314) 144-844

Thank you!