Practicing Lean 2016 Mark Graban Lean Frontiers

Mark Graban

@MarkGraban

www.PracticingLean.com

www.LeanBlog.org

Slides & More:www.MarkGraban.com/LALMS

Reflections on 20+ Years Trying to Get Better at Lean

in Manufacturing & Healthcare

www.louisebatz.org

Practicing Medicine

Practicing Law

Practicing Lean?

© Nicole Yearly (“chicagozen“ on Flickr), used under Creative Commons License

Implementing

Practicing

Learning

LearningBy

Doing

LearningBy

Doing**With a Qualified Coach

“I’m Jim Pell.I’ve been learning Lean for 25 years.”

LearningThroughMistakes

e

We AllMAke

Misteaks

One ofMy

Mistakes(2004)

“My” Kanban System

When inventory reaches 2160, take care to Level 4 Meterbody kanban board.

Qty to build: 660 units

Actual Build Qty:

“My” Kanban System

When inventory reaches 2160, take care to Level 4 Meterbody kanban board.

Qty to build: 660 units

Actual Build Qty:

Or…

eansisguidedlyxecuted

Or…Just not good

at this yet?

Their Kanban System

We All StartSomewhere

eansistakenlyxplained

“Toyota would tell you to kick the patient out of the

room at 19:59 because you have to keep on takt time.”

Dunning-Kruger EffectUnskilled and unaware of it: how difficulties in recognizing one’s own incompetence lead to inflated self-assessments – Kruger & Dunning (1999)

100%

0%None Experience Expert

Con

fiden

ce

We All StartSomewhere

“Which Lean Tool Should I

Start With?”

Start from need.

What problem are we trying to solve?

“Which Lean Tool Should I

Start With?”

“Always start with 5S”

“Always start with 5S?”

We’ve Always Done it

That Way

ToyotaProduction

System

ThinkingProduction

System

Learn, But Don’t Copy

eansisguidedlyxecuted

Right Tool, Wrong Culture

7 am

8 am9 am10 am11 am12 am1 pm2 pm

92

92

92

9292

92

9292

BLOCKS • Plan• Actual• Reasons why

Right Tool, Wrong Culture

Right Tool, Wrong Culture

7 am

8 am9 am10 am11 am12 am1 pm2 pm

92

92

92

9292

92

9292

BLOCKS60

60

60

6045

60

1430

My GM Mistakes• Ergonomic assist• Kanban tooling board• Calling out the manager• Quality or cost?

1996 Current State at GM

• Worst performing engine plant

• Worst performing part of GM Powertrain

• Worst performing part of GM N.A.

• Worst performing part of GM

• Worst performing automaker

"We were offering suggestions and getting pushback on safe

staffing, yet being told to reduce the number of pens and pencils.”

Or…

eansistakenlyxplained

“Go ahead and use Lean on that quality problem…

you’ll speed up your quality problem and make bad stuff faster.”

“Lean will help you to reduce or eliminate [wastes] 1 through 6.

Six Sigma will help you to reduce number 7 [defects].”

Jidoka Just-in-Time

“If lots of people are upset, it’s not really TPS.”

ComplainingAbout

Resistance

Complaining About Lack ofSustainment

“We were only holding the gains on about

40 percent of those

[Kaizen Events]”

Lack ofAdoption?

“We’ve been implementing Lean

for 5 years… now we’re focusing on

continuous improvement.”

WhyLean?

WhyLean?

90%??

Why BeBetter at

Lean?

• Don’t be afraid to make mistakes

• Learn from the mistakes of others

• Try to anticipate possible mistakes

• Make small mistakes to prevent big mistakes

• Don’t keep making the same mistakes

If You’re New to Lean…

• Share your early mistakes

• Call out “Fake Lean?”

• Be patient & respectful

• Always be a learner, and be making new mistakes

If You’re Experienced…

• Make sure you’re staying true to Lean without being too dogmatic

• Think about how people might misunderstand what you’re teaching

• Discuss pro-active countermeasures to L.A.M.E. or “Fake Lean”

If You’re Teaching…

Learn bydoing

Do it right the first time

Q&A / Contact Info• www.MarkGraban.com • www.LeanBlog.org• [email protected] • Slides & More:

www.MarkGraban.com/LALMS

www.PracticingLean.com