The Basics

As you look at opportunities for improvement and engage the workforce to assist in our LEAN ongoing approach to work, keep in mind the focus on types of waste that can be reduced, the Rules of Work and the LEAN manufacturing based Tools to achieve a more efficient future state. As we discussed this morning in CP "Share the Gain", this is a useful framework for summarizing the results of your LEAN projects that you present and serves to reinforce the quality lessons and culture we are creating with our workers.

FOCUS: 7 Seven Types of Waste

  • Overproduction, in excess of what's required
  • Waiting, downstream process inactivity
  • Transport, material & work-in-progress
  • Extra Processing, due to defects, overproduction or excess inventory
  • Inventory, excess requires additional handling and space
  • Motion, personnel & equipment
  • Defects, don't conform to specification or customer's expectation

RULES: 4 Rules of Work Design

  • Rule 1- STANDARD ACTIVITIES: Specifications document all work processes to include content, sequence, timing, location & expected outcome (how do you do your work)
  • Rule 2- STANDARD CONNECTIONS: Connections with clear YES/NO signals directly link every customer & supplier (requests & responses)
  • Rule 3- STANDARD PATHWAYS: Every product & service travels a predefined, single, simple & direct flow path (no looping or forking)
  • Rule 4- IMPROVEMENT & WORKER EMPOWERMENT: Workers at level where work is done, guided by a teacher, improve their own work, using data

TOOLS: Tools to Improve Workflow

  • Standard work
  • Mistake proofing
  • Batch size reduction
  • Level load
  • Work simplification
  • Visual displays, controls & and color coding
  • Andon white boards
  • Kanban

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