Lean Project Management Principles

1. Lean Project Management Principles What is lean?

2. Origins of Lean The Toyota Production System by Taiichi Ohno Various titles by Shigeo Shingo The Machine that Changed the World by Womack and Jones

3. Principles of Lean • Identify value • Map the Value Stream • Create Flow • Establish Pull • Seek Perfection

4. Seven Sources of Waste • The process • Methods • Movement • Product defects • Waiting time • Over-production • Inventory

5. Examples of these wastes in your office • The process • Methods • Movement • Product defects • Waiting time • Over-production • Inventory

6. Characteristics of Lean Environments • Flow manufacturing • Process flexibility • Total quality management • Total productive maintenance

7. Characteristics of Lean Environments • Uninterrupted flow • Continuous process improvement • Supplier partnerships • Total employee involvement

8. Importance of Lean Lean is not primarily an inventory reduction program. Its primary purpose is to focus attention on problems.

9. Deming on Lean The great advantage of the [Lean] system is the discipline behind it - processes in control; quality, quantity, and regularity predictable. Out of the Crisis

10. 5S’s • Sort:Organization (Seiri) • Set in order: Orderliness (Seiton) • Shine: Cleanliness (Shitsuke) • Standardized Cleanup (Seiso) • Sustain: Discipline (Seiketsu)

11. Five S • Sort • Set in Order • Shine • Standardize • Sustain RED TAG

12. Set in Order • A place for everything and everything in its place. • Tool cutouts • Taped outline on floor or bench

13. Set in Order • A place for everything and everything in its place. • Tool cutouts • Taped outline on floor or bench

14. Shine • Keep everything clean and swept • System maintenance and inspection • Problems (e.g., oil leaks) are more easily spotted when the workplace is in order

15. Standardize • Standardize ensures that your progress in 3S implementation is not wasted. • Procedures, schedules, practices

16. Sustain • Deming’s point number 1: Constancy of purpose • The leadership of supply is responsible for sustaining the process. • MBWA

17. Sources of Service Wastes • The process • Methods • Movement • Product defects • Waiting time • Over-production • Inventory

18. Advantages of Setup Reduction • Reduced EOQ • Reduced queue & mfg. Lead time • Reduced WIP • Improved quality • Improved process and material flow How does these related to product development / PM?

19. Reference • Decoding the DNA of the Toyota Production System, Steven J. Spear, Kent Bowen, Harvard Business Review, September, 1999.