LEAN Basics for Offices

1. LEAN Basics for Offices January 13, 2015

2. Maximizecustomer value while minimizing waste. What is “LEAN”?

3. Value Add Customer believes it is important; willing to pay for this task Physically changes the thing adding desired function, form, or feature Work is done right the first time Non-Value Add Task adds no value as viewed by the customer Examples include: correcting/reworking, expediting, multiple signatures, counting, handling, inspecting, set up time, downtime, transporting, moving, delaying, storing…etc. Necessary Non Value Add Process would break down if this task was not performed Required by law or regulation Task reduces financial risk What Is Value?

4. What Is Waste? Waste is “anything other than the minimum amount of equipment, materials, parts, space, and worker’s time which are absolutely necessary to add value to the product.” - Shoichiro Toyoda, President, Toyota

5. Value: what customers are willing to pay for • Value Stream: all the steps in our processes that deliver value to our customers • Flow: organizing the Value Stream to be continuous • Pull: responding to downstream customer demand • Perfection: relentless continuous improvement culture; A continuous journey

7. 7 GREEN Wastes Energy Water Materials Garbage Transportation Emissions Biodiversity B www.greenenterprise.ca

8. Lean Tools • Flexible Manufacturing System • Flow Chart. • Future State Map • Heijunka • ISO standards • JIT/Inventory Reduction • Jikoda • Kaizen Events • Kanban/Small Batch Sizes • Lean Supermarket • Level Loading • Mass Customization • Metrics Based Process Mapping • Milk Run • Mind Maps • One Piece Flow • One-Touch Exchange of Dies • Pareto Charts • Poke-a-Yoke/Error-proofing • S&OP • Six Sigma • SMART Goals • Single Minute Exchange of Dies (SMED) • Spaghetti Diagram • Standardized Work • Statistical Process Control • Takt Time • Time Study • Total Productive Maintenance • Value Stream Mapping • Visual Cues/Painted Floor • Visual Metrics • Visual Status Indicators • Waste Walk • Zero Quality Control • 2-Bin System • 5 Why’s • 5S • A3 Report • ABC Inventory • Benchmarking • Bottleneck Analysis • Cause and Effect (Fishbone) Diagram • Cellular Manufacturing • Check Sheet • Cross-training • Current State Map • Dynamic Scheduling • Empowerment • ERP • External Setups • Failure Modes and Effects Analysis (FMEA)

9. Lean Office Tools • Flexible Manufacturing System • Flow Chart. • Future State Map • Heijunka • ISO standards • JIT/Inventory Reduction • Jikoda • Kaizen Events • Kanban/Small Batch Sizes • Lean Supermarket • Level Loading • Mass Customization • Metrics Based Process Mapping • Milk Run • Mind Maps • One Piece Flow • One-Touch Exchange of Dies • Pareto Charts • Poke-a-Yoke/Error-proofing • S&OP • Six Sigma • SMART Goals • Single Minute Exchange of Dies (SMED) • Spaghetti Diagram • Standardized Work • Statistical Process Control • Takt Time • Time Study • Total Productive Maintenance • Value Stream Mapping • Visual Cues/Painted Floor • Visual Metrics • Visual Status Indicators • Waste Walk • Zero Quality Control • 2-Bin System • 5 Why’s • 5S • A3 Report • ABC Inventory • Benchmarking • Bottleneck Analysis • Cause and Effect (Fishbone) Diagram • Cellular Manufacturing • Check Sheet • Cross-training • Current State Map • Dynamic Scheduling • Empowerment • ERP • External Setups • Failure Modes and Effects Analysis (FMEA)

10. 5S – Haw River State Park Storage Area in Maintenance Shed

11. Spaghetti Diagrams

12. Value Stream Mapping

13. Selecting a Lean Project Start with a simple process… • With management support… • Important enough… • Or painful enough… • To get attention! Other Criteria…

15. Questions? Angela Barger angela.barger@ncdenr.gov 919-707-8126