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Why Lean Can’t Succeed Without Operational Discipline
Author:
Calvin Williams
Principal / Continuous Improvement Strategist
Manuficient Consulting
Manufacturing Strategy, Analytics, & Implementation
Perfecting the manufacturing system is an art; however, executing the One Right Way is an exact science
Manufacturing Art vs. Science
Art SciencePlant and Layout Design
Process design & engineering
Continuous Improvement
Changeover Execution
Performing Quality Checks
Developing Standard Work Procedures
Executing Standard Work
Performance Coaching and Feedback
Talent Development
Performing Root Cause Analysis
Executing Preventative Maintenance
Front-line supervisor / manager effectiveness can be measured in terms of the number of deviations from the One Right Way
Manufacturing Management Effectiveness
Operator A Operator B Operator C
Operator A Operator B Operator C
Maximize:• Quality• Service (reliability)• Morale
Minimize:• Cost• Safety Risk
Results
Disciplined Process Execution
+250%+140%
+321%
0% +10% +8%
Maximize:• Cost• Safety Risk
Minimize:• Reliability• Morale• Quality
Results
Identifying and becoming disciplined to One Right Way minimizes operating cost while maximizing reliability
Identifying and becoming disciplined to One Right Way minimizes operating cost while maximizing reliability
The ultimate measure of production management effectiveness is the disciplined execution of operations
Out of Control Process ExecutionIllustrative
Lean can be broken down into two base components: Industrial Engineering and Operational Discipline
Base Components of Lean Manufacturing
Industrial Engineering Operational Discipline
The process of designing and implementing the perfect manufacturing system
The consistency of actions taken to execute operations
Lean ManufacturingThe Systematic Elimination of Waste
New Plant or Process Design & Implementation
Plant or Process Optimization
Industrial Engineering is the process of designing and implementing the perfect manufacturing system
Components of Industrial Engineering
New Plant or Process Design & Implementation
Plant or Process Optimization
Optimization consists of continuously improving the performance of key aspects of performance
Cost Safety Risk Quality Service Morale
Plant / Process Design consists of creating and implementing a system of converting inputs into desired outputs
Examples of Lean (IE) Tools
Kaizen
Root Cause Analysis
Poke-a-yoke
Hiejunka
Kanban
Hoshin Kanri…Many Others
• Key Points
• Discipline can be driven without the application of Industrial Engineering
- It is the result of disciplined leadership• Operational Discipline helps to understand the
relationship between Six Sigma and Lean
Operational discipline is the consistency of actions taken to execute operations
Operational Discipline
Distribution of Process Completion TimesOut of Control Process Distribution Disciplined Process
Distribution
1σ 2σ 3σ 4σ2σ3σ4σ6σ
1σ 2σ 3σ 4σ2σ3σ4σ6σ
Front-line Supervisor / Management performance can be measured in operational discipline
Without operational discipline, Lean improvements cannot be sustained nor can estimated benefits be realized
Lean & Operational Discipline
ActualAverage
Target
-60%
-37%-68%-37%
-76% -76%
-62%
Process Execution Times
The gap between actual and target performance results in increased cost and reduced plant reliability
Actual Cost Target Cost
Missed Opportunity
Process Execution CostMaximize:• Cost• Safety Risk
Minimize:• Service (reliability• Morale• Quality
Results
Illustrative
We offer an array of services to help manufacturers across industries to realize their business objectives
Manuficient Service Offerings
Operating Cost Reduction
Optimize process efficiency to increase labor and asset utilization
Production Throughput Increase
Eliminate process bottlenecks to unlock untapped capacity
Material Cost Reduction
Close material loss points and/or identify favorable sourcing options
Business Case Analysis
Evaluate overall business impact to support decision-making
Should-Cost Analysis
Determine what a product should cost to make or procure
Network Optimization
Assess the optimal manufacturing footprint and associated benefit
Efficiency & Opportunity Analysis
Provide on-going process improvement support
All services are founded in principles of Lean, Six Sigma, Agile Manufacturing and other leading disciplines designed for operational excellence
Contact Details
Calvin L. Williams, MBA, BSIE, LSSPrincipal / Continuous Improvement Strategist(404) [email protected] Manuficient ConsultingManufacturing Strategy, Analytics, & Implementation2300 Holcomb Bridge Rd Suite 103-103Roswell, GA 30076www.manuficient.com Visit my Excelville Profile for tools and resources for your operations excellence initiative. Engage with us:Subscribe | Request Material | Schedule a Call | Request a Proposal Connect with us:Facebook | Twitter | Linkedin | Google+ | Blog
