Lean Methodology

Musings from a Lean Thinker

Originally used as Lean Manufacturing used by Toyota. Remove waste in each phase, so that only value is added.
Implement Lean project management when you want to use limited resources, reduce waste, and streamline processes to gain maximum benefits.

5 Principles of Lean

Define value

Map value stream

Create flow

Establish pull

Pursue perfection

Fundamentals

Eliminate Waste
- Look early and often for waste
- Anything that does not add value to the product/service
Focus on business processes
Mistake Proof your Processes (Poka-Yoke)
- Create ways to eliminate any chance for error
- Physical restrictions, visual cues, templates, workflow order
Processes should be “Pull”, not “Push”
- Pull: determined by customer demand — only provide what is required
- Push: determined by process — produce what we “guess” will be needed (or our forecast!)
Defects are not made and/or passed along
- Defects are prevented whenever possible, but never moved to the next step in the process
Level & Balanced
- Workload design based on demand (tact time)
- Minimize non-value-added steps
- Multi-skilled employees perform more than one task

Intellect: Failure to fully utilize the time and talents of people; lack of training
Motion: Any motion that does not; add value; chasing parts, signatures, tools, etc
Defects: Any rework; errors
Overproduction: Producing too much; producing too soon; batch processing
Extra Processing: Adding inspections; approvals; reviews
Transportation: Any nonessential transport or handling
Inventory: High supply stores; finished product stores; in-work materials
Waiting: Waiting on parts or documents, waiting for other workers or a machine

Buy-in from entire team
- Current attitudes
- Trust as a core building block
- Future commitments
Sustaining gains
Continuing to improve
Cultural change