Big 12 Lean Approach 2

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Information about Big 12 Lean Approach 2
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Published on November 7, 2007

Author: Moorehead

Source: authorstream.com

Lean Approach:  Lean Approach For Small Project Development Process Customer Feedback Self Study Focus Group:  Customer Feedback Self Study Focus Group Projects are seen as expensive and long Customers expect on-schedule and in-budget performance Insufficient consultation at the start of the process Not enough questions are being asked, answers are not listened to carefully Cost of design feel exorbitant, “word on the ground” is to avoid design Schedules are not clearly communicated Flow and sequence of work does not appear to be “sensible” Quality of work is high, but pace and cost not satisfactory End up as our own project manager, need a supervisor or project manager – one contact for us Four Headed Dragon Past Key Process Owners:  Four Headed Dragon Past Key Process Owners Work Information Design Services Work Planning and Estimating Construction Support (Bldg Maint) Reduce Cycle Time:  Reduce Cycle Time “One of the most noteworthy accomplishments in keeping the price of Ford products low is the gradual shortening of the production cycle. The longer an article is in the process of manufacture and the more it is moved about, the greater is its ultimate cost.” Henry Ford, 1926 Lean Is:  Lean Is A systematic approach for identifying and eliminating waste through continuous improvement. Lean:  Lean Standardized Work Operations safely carried out with all tasks organized in the best known sequence, and using the most effective combination of these resources: People Materials Methods Machines Environment Lean Approach Small Project Development Process:  Lean Approach Small Project Development Process Team, Self Empowered Cross-trained and multi-skilled employees Continuous improvement philosophy Process quality, not inspection Use of participatory decision-making Team-based problem solving, suggestion systems, etc. Value Stream Mapping Tool Used to Analyze Project Development Process:  Value Stream Mapping Tool Used to Analyze Project Development Process Step 1 - Creating a clear picture of current material and information flow Step 2 - Creating picture of improved flow and eliminating waste Value Stream Mapping Process Review:  Value Stream Mapping Process Review Review Work Sequences Observe sequence of tasks each person performs Break operations into observable elements Identify value added versus non-value-added (NVA) elements and minimize NVA Waste Examples Non-Value Added Items Can Be:  Waste Examples Non-Value Added Items Can Be Overproduction Inventory Transportation Waiting Motion Defects Underutilized People Non-Value Added Processing Review of Typical Project Development Process:  Review of Typical Project Development Process Step One Value Stream Mapping of Process Production time………159 days “B” estimate…………..2 days Final design…………..17 days Planning /estimating…8 days Value added time…….190 hours “B” estimate……….……9.5 hours Final design…………….11 hours Planning/estimating..…..4 hours Process Improvement:  Process Improvement Lean Approach Experiment:  Lean Approach Experiment Lean team experimented with small project development process Trial 1, processed a simple project under existing process : 24 handoffs Trial 2, processed a complex project under existing process : 15 handoffs Trial 3, processed trial 2 under Lean process : 4 handoffs Continue to refine Lean process Begin discussion on new group name New Project Development Process Goals:  New Project Development Process Goals Design and Develop Team Design goals Flexible layout Close Proximity Simplify Flows Integrate process operations Minimize Information Handling Concentrate on value-added motions Update documents and web sites Make Use of People 100 Percent Promote visibility and flexibility Small Project Analysis:  Small Project Analysis What Was Done:  What Was Done Project Coordination Center Identified key volunteer team members Created work space Relocated team members Web site Support documents Measurements Project Coordination Center Six Staff:  Project Coordination Center Six Staff Key Process Owners Today:  Key Process Owners Today Design Services Project Coordination Center Construction Support (Bldg Maint) Event Score Card:  Event Score Card Project Close Measurement:  Project Close Measurement Project Close Measurement:  Project Close Measurement Project Close Measurement:  Project Close Measurement Project Close Measurement :  Project Close Measurement UCL LCL Project Close Measurement :  Project Close Measurement UCL LCL Project Close Measurement:  Project Close Measurement Sigma Performance Defects per Million Opportunities:  Sigma Performance Defects per Million Opportunities Sigma Level 1 sigma = 690,000 2 sigma = 308,537 3 sigma = 66,807 4 sigma = 6,210 5 sigma = 233 6 sigma = 3.4 Lean Approach Keys to Success:  Lean Approach Keys to Success Prepare and motivate people Widespread orientation to CI, quality, training and recruiting workers with appropriate skills Create common understanding of need to change to Lean Employee involvement Push decision making and system development down to the “lowest levels” Trained and truly empowered people Share information and manage expectations Identify and empower champions Remove roadblocks (i.e., people, layout, systems) Make system both directive and empowering Support ideas and encourage them to do their best Lean Approach Leadership Solution for Success:  Lean Approach Leadership Solution for Success Model, mentor, monitor, motivate, multiply Support ideas and encourage each other to do your best Attitude, process, tools Quality, cost, speed (better, cheaper, faster) Work in terms of processes, not individual performance Process system diagram Process System Diagram:  Process System Diagram Challenges:  Challenges Fear of loosing job Reluctant to change Comfortable with current tasks Don’t want to move Didn’t understand current process Historical animosity toward work groups Desired Outcomes From Onset:  Desired Outcomes From Onset No one loses a job Self empowered team environment Learn new skills Honor Commitments Higher productivity Satisfied customer Value Stream Map Examples:  Value Stream Map Examples See Display Slide33:  Questions Thanks

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