Lean Training for your lean journey

 

Lean Principles

Lean Objectives foundational to your Vision and Values for lean continuous improvement

Lean Principle # 1

Every Lean Implementation is an Invention

cookie cutter

There is no such thing as 'cookie cutter' lean

You can't just "do over here what they did over there".

You can't just "hire someone who used to work at Toyota".

You can't just "buy some lean tools with online training",
and then expect them to be used effectively.

(despite all of our efforts to try to come close to that ideal...)

Tools do no answer the question of "why", only the question of "how".

A guiding principle answers the question of "why".

When people understand why, they become empowered... to make good decisions.

~ Excerpts from the Shingo Model Handbook


Lean Principle # 2

Don't Reinvent

Yes, Lean Principle # 1 is "Every Lean Implementation is an Invention"

but that doesn't mean that you want to start from a state of ignorance.

Start with field-proven Lean Systems

and then... make them your own

These Lean Principles are Common to any Lean Systems

As you continuously improve your own lean systems for your own unique organization and culture,
make sure that your inventions always stay true to these 'True North' lean principles.

There are more principles of lean

As you progress on your own lean journey,

you will discover additional lean objectives and ideals,
but this is a pretty good list to bookmark and come back to... often.


Bookmark = ideals

Lean Principle # 3

Lean Ideals provide 'True North' direction

Lean Ideals are impossible...

compass

That's why they're called ideals.

Their purpose is to provide 'True North' direction —
toward which every member of your organization is commonly striving,
and yet will never fully reach.

Lean Ideals are a vision...

If your organization has a written Vision Statement,
it will undoubtedly include most of the following lean objectives and ideals
that are common to every lean organization.

And if your organization does not yet have a Vision Statement,
then you might save some time and just get started with these...


Bookmark = targets

A Strategic Challenge

is the link between PDCA and your Strategic Plan

Lean Principles and Ideals are too vague and distant
to serve as useful guides for daily kaizen and PDCA Coaching Cycles.

Even your Strategic Plan or Annual Hoshin is too high-level
to serve as a useful guide for daily process improvements.

A shorter-horizon 'Strategic Challenge' (established by your mid-level manager)

provides a clear direction for what is needed from your team
to support the other teams that will depend on you when you all reach the next resting place
on your never-ending lean journey toward your never-changing lean principles.

Strategic Targets are the links between PDCA and your Strategic Plan

Criteria for a Strategic Challenge

Your mid-level manager needs to come up with a Strategic Challenge
for your Value Stream and/or Department that meets the following criteria.

1. A compelling description of a desirable state

A process breakthrough that will bring competitive advantage

Condensed to a compelling short rallying cry to focus the team's attention and effort.

Examples:

Wouldn't it be great if we could... Rally Cry
make any item the same day that it's ordered, and ship the next day Ship tomorrow
get the results of any lab test back within 2 hours Know today
completely eliminate safety accidents No accidents

2. Far enough away to be a stretch

It can't be done with existing processes in their current conditions

3. Believable

Close enough to be within reach
(believably achievable within 3 to 30 months)

4. Clearly defined outcomes

Clearly defined measures and targets for process results that must (somehow) be achieved

The leader for each area of responsibility works with his or her coach
(at the next higher level)

to determine the capabilities needed from each value stream, value stream loop, department, process, and supporting function — in order to support the stretch goals of the next higher level

Scoutmaster

Navigating unknown territory?

Use PDCA Coaching

thereby uniting every effort at every level of the organization
to pull together to support the highest level strategic plan.

5. Many possible options to reach those outcomes

Plenty of options for scientific experimentation
for HOW to produce those desired outcomes

Puzzling enough that the details for how to reach those measures
are not already obvious

If there is no "unclear territory",
then you have set your Strategic Targets too low

What's the point of conducting PDCA scientific experiments
if you think you already know the answers?

How to come up with your next Strategic Challenge

Value Stream Map

The most common way to identify potential strategic targets
is to create Current State and Future State Value Stream Maps.

What does each value stream need to deliver?

What does each loop within each value stream need to deliver?

      A "loop" is a section of a value stream

Money flow

Why is flow so important?

Start with Flow

As explained in our online training for What is a Lean Journey?

If you still have any value stream
(or segment of a supporting value stream)
that is not yet in a sustainable state of lean flow...

then there should be nothing strategic to think about.

The strategic challenge for that value stream (or segment)

needs to start with Lean Flow

See more training for how to choose a well-considered Next Target Condition


 
 

Bookmark = Reading

Suggested Reading and Resources for

the Principles of Lean

Remember, whenever you don't immediately find what you're looking for,

you can browse the Systems2win Site Map

or use Google Site Search (in the upper right corner of every web page)

The Shingo Model

The Shingo Principles of Operational Excellence
provide a comprehensive and well-thought-out summary of lean principles.

Shingo Principles

Source: Shingo Institute

You can download the Shingo Model Handbook and Poster at shingo.org/model

After you download your (free) handbook,
you will want to set aside about an hour to read and thoroughly digest their:

Tools do no answer the question of "why", only the question of "how".

A guiding principle answers the question of "why".

When people understand why, they become empowered... to make good decisions.

~ Excerpts from the Shingo Model Handbook


More Lean Principles

A frequently cited reference for Lean Principles is Jeffrey Liker's book, The Toyota Way.

 

5 Steps of Lean

 

 

 

 

 

 

 

When you search for 'Lean Principles' within
The Lean Enterprise Institute, (lean.org),
you will find their 5 Steps of Lean

as well as an interesting article about early sources of lean principles — pre-dating Toyota.

And Business Basics
offers DVD's, seminars, workshops, and events
Lean Manufacturing Training


Lean Manufacturing Principles

What's the difference between Lean Principles
and Lean Manufacturing Principles?

Nothing.

It doesn't matter whether the process that you are improving
is for lean healthcare, or lean office, or lean service, or lean government...

Lean principles, objectives, and ideals remain the same.

Learn more about Lean Manufacturing Principles


Bookmark = rules

The Toyota 4 Rules In Use

In their paper Decoding the DNA of the Toyota Production System, Harvard Business Review, 1999,
Steven Spear and H. Kent Bowen boiled down the essence of all lean systems to these Lean 4 Rules In Use:

Rule 1) Clearly specify all Activities

Standardize work

Rule 2) Clearly define all Connections
to every customer and supplier

No ambiguity

Rule 3) Clearly define all Pathways

Organize for uninterrupted flow

Rule 4) Continuously Improve

Develop leaders who can apply the scientific method to improve anything


A3 Interview  

The Gemba Interview Questionnaire

Use your Gemba Interview Questionnaire (gemba-interview.xlsx)
to ensure that you:


Learn even more about the Principles of Lean

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