Advanced Lean Tools Building on the basics Process Preparation (2P)

1. Advanced Lean ToolsBuilding on the basicsProcess Preparation (2P)

2. 2PProcess preparation Used primarily to develop a process for a new product or service, or where the current process is so unclear or indistinct that that really doesn’t exists

3. 2P Is a facilitated, team-based design process, that uses simple tools and the creativity of the team to develop a high quality, efficient, value-added process.

4. Can you think of work that you do, where you are unsure if there is a process, or what the process might be?

5. 2P steps • Clearly understand process outcome • What are the key customer requirements? • Define the scope • Develop alternatives • Narrow and evaluate alternatives • Agree on a proposed new process • Simulate the new process • Document new process • Create standard work • Create implementation plan

6. 1. Understand the process outcomes • What is the widget we are making? • How many widgets will we need to process each week/month/year? • Who is the customer for this widget?

7. 2. What are your customers key requirements? • Speed? Accuracy? Convenience? Value? Consistency? All of the above? • What must the process produce on a consistent basis to create customer satisfaction

8. 3. Define the Scope What is the first step and the last step of the process you are preparing.

9. 4. Develop alternatives • Break the kaizen team into two or three groups with facilitation assistance • Each group separately develops a proposed new process, or, develop two or more proposed portions of a new process that will meet customer requirements

10. Build a new Swim Lane Map Customer Service sends e-mail to Sales Customer Calls in order. Sales person is assigned to order and delivers paper copy of order to Order Entry Customer Customer Service Sales An electronic order is sent to the supplier. Order Entry Order is now entered into the company’s data base. Accounting Supplier Shipping

11. 5 . Narrow and evaluate alternatives • Reconvene, and have each group present their options and proposals • Have the full group identify the best elements of each proposal • Gain consensus on the best elements of each, and document

12. 6. Develop a new process • Use a swim lane mapping tool, to display new process • Review map for waste, rework, duplication. Can any part(s) of the process be run concurrently?

13. 7. Simulate the process, or as much of it as you can From the beginning To the end

14. Understand and define the roles and relationships of each function and step within the new process 8. Document the new process

15. Questions to ask as you document the new process Where does this information come from What is an acceptable amount of wait time for this process step to be completed Where does the information go from here Does the information need to go to more than one place Is there new information or is it the same information being translated into another form

16. 9. Create new standard work • Develop necessary forms, describe how each task in the new process is to be done. • Establish task and wait times for each step in the process

17. 10. Create the implementation plan • Establish a workplan with timelines and responsibilities for each task that needs to be completed to implement the new process • Accountability of the team, or work unit is essential to insure proper implementation and sustainment

18. ?????Questions?????