Lean Process Excellence Flashcards
Operational excellence (what is it)
Operational excellence is the alignment of people, technology & data to optimize decision making and drive continuous value to our members.
Five Lean Principles
- Identify member value
- Identify and Map the Process
- Create flow by eliminating waste
- Respond to member pull
- Pursue perfection
Lean Process Rules
- Everything we do is a process, and we want value to flow through our processes.
- All processes have variation and waste
- All variation and waste have a root cause
- Known root causes should be eliminated, reduced or controlled
5.All customers have suppliers and all suppliers have customers.
Metrics Based Process Map (MBPM)
What is the purpose?
Immediate feedback on potential waste, bottlenecks or possible improvements.
Allows for a person to walk, interview, document and measure all steps in a process.
Not recommended to discuss improvements, only document them.
Metrics Based Process Map (MBPM) - headers
From left to right:
1. Role (person)
2. Function (what needs to be done)
3. System(s)
4. Time (mins)
5. Result (deliverable)
6. Dependency (what is required to do this step)
What is a Lean Process - A process which produces
- What the customer wants value
- In the quantity the customer wants demand
- When the customer wants it schedule
What is a Lean Process?
While using minimum resources (hint tempo)
Time
Equipment
Materials
People
Operations
What is a Lean Process - eliminate Bottlenecks
Can only go as fast as your slowest process step
Process Improvement by PDCA
Combining Lean and PDCA/A3 for process Improvement
Lean Methodology
- Identify Value
- Map the Process
- Create the flow by eliminating waste
- respond to customer pull
- Purse continuous improvement
Process Improvement by PDCA
Combining Lean and PDCA/A3 for process Improvement
PDCA - A3 Template - Plan
Plan - 1. Define problem statement
Plan - 2. Measure the current state
Plan - 3. Set Target Goals
Plan - 4. Analyze the root cause
Process Improvement by PDCA
Combining Lean and PDCA/A3 for process Improvement
PDCA - A3 Template - Do
Do - 1 - propose solution
Do - 2 - implement Solutions
Process Improvement by PDCA
Combining Lean and PDCA/A3 for process Improvement
PDCA - A3 Template - check
Evaluate results and processes
Process Improvement by PDCA
Combining Lean and PDCA/A3 for process Improvement
PDCA - A3 Template - Act
Act - 1- Follow up Actions
Explain what is an implementation plan
How your recommended countermeasures will impact the root cause to change the current situation and achieve the target.
- List of all relevant countermeasures with focus on the most impactful solution.
- Communicate proposed solution to stakeholders
Implementation Plan Template
Problem Statement:
8 items below - 3 large horizontal 5 vertical
1.) Root Cause (why) - large horizontal
2.) countermeasure / proposed solutions (what) - large horizontal
3.) feasibility - small vertical
4.) Specific Actions (how?) Large horizontal
- Effectiveness - small vertical
- Overall - small vertical
- Action - (who?) small vertical
- Value ($/period)
Explain what is a SIPOC
A diagram used in Lean methodology to identify key stakeholders and the current state of a process from a high-level view of the workflow.
( Key component to understanding a process in order to create a problem statement in your A3 template)
SIPOC Map Template
Supplier
Input
Process
Output
Customer
UNDER PROCESS
1. RFI /RFP / RFQ process completed >
2. Business lead submits a project intake request and business case >
- Process excellence and Executive team reviews >
- Vendor due diligence performed >
- Vendor Selected
A3 / Kaizen problem solving template
(Plan)
Define problem statement
Explain what issue you want to solve.
How is it impacting org?
Provide relevant background
Measure the current State
What is the current process
Include a SIPOC diagram
Provide any metrics regarding the issue
Target(s)/Goal(s) of the future state
What is the specific change you want to accomplish now.
Diagram the desired state.
Include measurable targets -how will you measure success?
Root Cause Analysis
The root cause(s) of the problem.
-Why are we experiencing the symptom?
-whay constraints prevent us from the goal?
Choose the simplest problem solving tool for this issue:
-5 Whys
-fishbone
-QC Tools
A3 / Kaizen Problem Solving Template (Do)
Proposed Solution/ Implementation Plan
How your recommended countermeasures will impact the root cause to change the current situation and achieve the target.
Provide an implementation plan for your solution
-What is being changed?
-Who will do the work?
-When will this take place?
A3 / Kaizen Problem Solving Template (Check)
Effect Confirmation
-Provide measurable results of what the solution achieved.
-Define KPI’s of the new performance/ impact
-Identify the sources of the data
-Who is responsible for the ongoing measurement of the new process?
A3 / Kaizen Problem Solving Template (ACT)
Follow up Actions
How do you plan to:
Standardize the new process.
Communicate the process to other teams.
