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Achieve Lean Excellence
Learn-Share-Grow Webinar Series
Professor Peter Hines
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Welcome Webinar will last about 1 hour
We will invite you to completea few Polls
Q&A session
Our Webinar
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Professor Peter Hines
Co-founder Lean
Enterprise ResearchCentre, Cardiff University
Chairman, S A Partners Adjunct Professor,
University of SouthAustralia
Welcome!
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Muda, Mura and Muri
Mura
(unevenness)Muda
(waste)
Muri
(overburden)
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Lack of a clear executive vision Lack of an effective communication strategy Failure to create and communicate a real sense of urgency Poor consultation with stakeholders
Lack of structured methodology and project management Failure to monitor and evaluate the outcome Failure to mobilise change champions Failure to engage employees
Absence of a dedicated and fully resourced implementationteam Lack of sympathetic and supportive Human Resources
policies
Top 10 Reasons for Failure
Source: Lucey, Bateman & Hines, 2005
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Kaizen Blitz vs. LeanManagement
I m p r o v e m e n t O p p o r t u n i t y
Time
Short termgains made
Lost and repeated resultsdue to no sustainability
Results could be lost entirelyif organizational structure notaligned to support and educationlevel of all employees not increased.
Improvement leveled off andeventually stopped due to lackof realizing true leanopportunity
Greater, sustainedresults achieved
Awareness, education,organisation structurecreated to support lean Source: C. Craycraft, Whirlpool
Utilization of Lean tools will deliver
performance improvement. However,behaviors focused on Continuous
Improvement / Pursuit of Perfection willprovide sustainable long term
improvement
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Is your lean programme closer to the kaizen blitzapproach or true lean approach?
Please select one or the other
Poll
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Sustainable Lean Management
Lean Management
Source: P. Hines, P. Found, G. Griffiths & R. Harrison, Staying Lean, 2008
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Cogent Power Case
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An urgent need for change
Substantial Pre-tax losses in 2003 from Global operations Business was losing cash from a number of its Operating
Plants Seven Global Operating units Relatively Static order book with emphasis towards lower
margin products New CEO put in place to Lead the business TURNAROUND
strategy Experienced Senior Management Lean Team appointed to
support
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Internal Value Stream focus
Hines, Found, Griffiths & Harrison, 2008
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The roadmap to sustainability
4
3
1
2
Roadmap 1
Launched Jan 2004
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Roadmap 1: StrategyFormation & Deployment
Leadership structure confirmed and aligned to the turnaround Kicked-off with top level awareness & Strategy sessions International & regional management teams CSFs & KPIs Lean message communicated from the top to help
deployment
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Roadmap 1: People Skills andValue Stream Mgt
Selection process to ensure that the right coaches chosen Extensive Lean coach programme theory & practical Lean coaches developed hands-on experience in tools Steering team meeting and best practice sharing events
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Roadmap 1: Internal VSM andLean Toolkit
Visual Impact with 5S, TPM & SMED at all sites High levels of engagement with site cross-functional teams Process stability being used to help introduced pull systems Gold Star standards using 6 Sigma set for heavy industry
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Roadmap 1: Basic Customer Value& Office Lean
Customer Value assessments for all businesses Sales acquisition mapping used to improve order creation process Office 5S used to improve sales requisition process time Lean tools and deployment evident in many support areas
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Maturity AssessmentBusiness to business benchmark
Stage 1Reactive
1. Reactive Approach2. 2. Little / No
Involvement3. Adhoc Learning
Stage 4Autonomous
Stage 5Way of Life
Stage 2Formal
Stage 3Deployed
1. Formal Structure2. Only Specialists3. Team Learning
1. Goal Oriented2. Selected Team3. Value Stream
Learning
1. Autonomoushabit
2. FullEmpowerment
3. External Learning 1. Driven Deployment2. Majority
Involvement3. X-process Learning
Key Characteristics
1. Ways of Working 2. Employee Engagement3. Learning Best Practice
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A Sustainable Journey
R
ve
F
ma
D
oe
A
o
mo
W
o
fe
Mo
sao
B e n e f i t
Time
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Which stage of this journey do you think you are?
Please select one answer
Poll
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Organisational LearningLean Maturity Assessment
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Organisational LearningLean Maturity Assessment
The coaches have become the leaders of Lean Real Lean management is still an exception LEAN is too cosmetic and not fully impacting profit LEAN still seen as an initiative and not given
priority OEE and Pareto are hardly used to drive
improvement
Lean is not driving changes in managementbehaviour Responsibility and accountability not fully deployed
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Maturity Assessment: Under theWaterline
Unstable IcebergModel
Technology, tools andtechniques
ABOVE WATERLINE - VISIBLE ABOVE WATERLINE - VISIBLE
Supply chainintegration
Processmanagement
UNDERWATER - ENABLING UNDERWATER - ENABLING
Behaviour and engagement
Strategy and alignment
Leadership
Enabling Features Not Fully Addressed
NARROWING UNDER WATERLINENARROWING UNDER WATERLINE
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The Roadmap to Sustainability
Roadmap 2
Reviewed July 2005
3
2
1
45
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Roadmap 2: Multi-level Leadership& Deployment
Leadership developed at every level of the organisation (7Values)
Clearly defined roles & behaviours for self-managedteamworking
Re-deployed targets aligning OF / OC / NPI processes Full line of sight deployment locked into key processes
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Roadmap 2:Lean and the Extended Enterprise
Focus on sustained profitability in strategically selected areas Sustained operational performance metrics on key Value
Streams Aligning supplier and customer processes via CAMBAN
technology Operational capability now leading to sales growth opportunities
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Roadmap 2: Customer Value &Supplier Integration
Detailed Customer Value extending throughout the supply chain Adapting process to meet with Customer & business needs Product / process development exceeding Customer
expectations Extending the offering and bridging the supply-chain
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Lesson: Focus Under theWaterline
Focus below the waterline in order to deliver the sustainable businessresults required to keep you continuously above the waterline
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Lowering the Water Level
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Lowering the Water Level
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Which elements of the Lean Iceberg do you need topay more attention to?
Strategy & Alignment Leadership Behaviour & Engagement Tools & Techniques Processes
Multiple choice with multiple answers
Poll
S F f S i bl
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Success Factors for SustainableChange
L M t it d
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Lean Maturity andOrganisational Learning
Ad-hoc FormalGoal
orientedManaged
AutonomyWay of Life
A c h i e v e
m e n t
Knowing Organisation
Understanding Organisation
Single looplearning
Double looplearning
Step change in learning occurswhere the organisation can achieve
higher results than previously imagineddue to lack of knowledge of what waspossible
Bessant& Caffyn
McGill &Slocum
Senge
Push
Lean PullLean
Thinking Organisation
Learning Organisation
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What further activity would you like?
Please select one or more answers
Poll
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If you would like to discuss anything coming out of the webinar please contact me at:[email protected]
or +44 (0)7974 416660 Please also link up with me at
uk.linkedin.com/in/profpeterhines/
Further Questions
mailto:[email protected]://uk.linkedin.com/in/profpeterhines/http://uk.linkedin.com/in/profpeterhines/http://uk.linkedin.com/in/profpeterhines/http://uk.linkedin.com/in/profpeterhines/mailto:[email protected]7/27/2019 Achieve Lean Excellence LSG 0800
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Cardiff University accredited training in Melbourne,Sydney and Brisbane. See more details on:http://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdf
Lean and Green free webinar with Dr Keivan Zokaeion the 4 th June . See more details on:http://www.sapartners.com.au/thought-
leadership-in-the-area-of-lean-and-green-2/ Or Contact our Australian MD Chris Butterworth on
Australian Events
http://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/mailto:[email protected]:[email protected]://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/thought-leadership-in-the-area-of-lean-and-green-2/http://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdfhttp://www.sapartners.com.au/wp-content/uploads/2012/11/Lean-Awarness.pdf7/27/2019 Achieve Lean Excellence LSG 0800
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Staying Lean Event 5th
July Birminghamhttp://www.sapartners.com/staying-lean-thriving-not-just-surviving/
Learn-Share-Grow Event June 24 th & 25 th at Genzyme Waterford,Irelandhttp://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/
The Book Launch of Creating a Lean & Green Business System,June 20 th at The Bridge House, Tower Bridge Road, Londonhttp://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/
European Events
http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/book-launch-of-creating-a-lean-green-business-system/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/learn-%E2%80%A2-share-%E2%80%A2-grow-achieve-lean-excellence/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/http://www.sapartners.com/staying-lean-thriving-not-just-surviving/