LEAN Event Structure

Gilmore LEAN Team June 2013

1
Content

Goals
Introduction
Planning and preparation
Event
Follow-up
Summary

2
Goals

To know the structure of a LEAN event and to be able to explain

To understand the role of the Kaizen Leader in a LEAN event

To be able to apply the content of this lesson in order to

perform a successful LEAN event

To be confident to perform LEAN events

3
Content
Goals
Introduction
Planning and preparation
Event
Follow-up
Summary

4
What is a LEAN event?
Purpose is to improve a specific problem / area
Linked directly to a Customer Benefit: Safety, Quality, Delivery,
Cost
Can be linked to waste elimination: Floor space reduction, WIP
reduction, etc.

Lean event theme is chosen by process owner

Facilitated teamwork by a selected group of 5 to 12 people
Cross functional
Involved in the affected process
Freed up for doing so

Apply one or more LEAN tools

Typically lasts 2 to 5 days

5
Different types and names of LEAN events

6
Corner stones of a successful LEAN event

LEAN Tools

7
3 Phases of LEAN Events

CHE
CK
PLAN DO
&
ACT

PLANNING & FOLLOW-

EVENT
PREPARATION UP

PLAN: Establish the objectives and processes necessary

to deliver the expected output
DO: Implement the plan, execute the process, make the
product.
CHECK: Study the actual results and compare against the
expected results
ACT: Request corrective actions on significant
differences between actual and planned results.
8
Content

Goals
Introduction
Planning and Preparation
Event
Follow-up
Summary

9
Brainstorming Exercise: Planning and Preparation

Think about events you have already experienced or those you

are going to perform. What will be the important things to think
about and to do before starting a LEAN event ?

Write as many items as you can on a list.

Prepare to share your ideas with the group

Time 3 minutes

10
Typical LEAN event structure

PLANNING & FOLLOW-

EVENT
PREPARATION UP

Select a topic and set targets for the workshop which meets stakeholders
expectations
Select participants
Select an area
Define scope
Select a problem for improvement
Communicate the plans to entire company
Select the team leader, team members and train them
Go take pictures of the area before the event
Prepare the area (support, materials, background information)
Schedule the event
11
Typical Stakeholders in LEAN Events

Participants
Production Supervisor/ Sponsors / Trainer / Facilitator
Management
General Manager
HR Manager
Customers
Suppliers
Subject matter experts

12
Content

Goals
Introduction
Planning and Preparation
Event
Follow-up
Summary

13
Typical LEAN event structure

PLANNING & FOLLOW-

EVENT
PREPARATION UP

Kickoff and communicate the event goals and objectives, scope, etc.
Introduction to Proserv LEAN and training on the tools to be used
Analyze current state, go-see, collect data
Develop solutions that address the true root cause
Define measurements to ensure changes were successful
Plan, deploy and implement solutions
Evaluate, standardize, check improvements
Perform Hansei after completing the last task of the event
Final presentation to management and management approval for further
actions

14
Analyze current state, go-see, collect data

Often used tools:

Interviews
Survey
Time measures
Spaghetti diagram
Process analysis
Process map
Check-sheet / Tally sheet
Histogram
Pareto (80/20) analysis
Value Graph
Multi-voting
15
Develop solutions that address the true root cause

Often used tools:

Brainstorming
Fish-bone diagram (cause and effect)
Countermeasures matrix
5 Why (5 Why Analysis)

16
Evaluate, Standardize, Check Improvements

Often used tools:

KPI (Key performance Indicators) charts
Flow charts
Gantt diagrams
Pert diagrams
SOP (Standard Operating Procedures)

17
Content

Goals
Introduction
Planning and Preparation
Event
Follow-up
Summary

18
Typical LEAN event structure

PLANNING & FOLLOW-

EVENT
PREPARATION UP

Present the results of the LEAN event to the Sr.Management

Celebrate the completion of the event
Check implementation and results
Follow-up

19
Role of the Kaizen Leader

Responsible for guiding the group throughout the event

Help the group to successfully meet the event objectives
Co-ordinate with management
Mentoring of line managers in improvement activities
Proposal of workshop topics and coordination of organization
Preparation and conduct of LEAN events
Provider and collector of needed information
Training of participants in LEAN principles and tools
Conveying methods and selection of tools
Actively share experiences and learnings within the Proserv LEAN
Community
Update of Value Stream Maps and data collection

20
Content

Goals
Introduction
Planning and Preparation
Event
Follow-up
Summary

21
The process flow of a Kaizen event

Analyze
actual
situation

Present and
recognize
team results

22
Feedback

What do you have to be aware of as a Kaizen leader in

organizing or executing a LEAN event ?
Please think about this for two minutes and then discuss with
the group

23
Don't forget
Important things to be concerned before starting a LEAN event:
Define the area
A problem is chosen
A baseline is determined
Improvement target and measurements established
Leaders and teams are selected and trained
Timeframe for the event is set
Be sure:
to have adequate advance production to cover people that will
participate in the event
to involve employees in creating the solutions. Everyone included

must be trained
that process owners are not imposing their ideas on employees
that you understand the importance of preparation and follow-up
24
Conclusion
LEAN events should be held to make focused changes in the
workplace. They should be
Carefully prepared
Well coordinated
Thoroughly followed up in order to be successful

Thorough communications to those involved in the LEAN activities will

make the difference in whether your event succeeds or does not.

25