Over Production
More than needed or before it is needed.
Fast food: Make too much food
Lean is simple.
Three ideas, eight wastes, and a habit of improving a little every day.
1
Deliver value from your customer’s perspective
2
Respect for people and resources
The time of my customer and the time of my worker, and the resources required to make everything happen.
3
Eliminate waste
Eight kinds, below. Learn to see them and they start to disappear.
Eliminate waste
The 8 wastes.
Each one with an example from a fast food kitchen.
Transportation
Unnecessary movements of products & materials.
Fast food: Transfer food from the kitchen
Excess Inventory
Excess products and materials being processed.
Fast food: Extra food sits in inventory
Defects
Efforts caused by rework or incorrect information.
Fast food: Customer doesn’t want pickles
Over Processing
More work or higher quality than is required by the customer.
Fast food: Pickles have to be removed from food
Wasted Motion
Unnecessary movements by people (e.g. walking).
Fast food: Wasted motion from reworking finished food
Waiting
Wasted time waiting for the next step in a process.
Fast food: Customers are waiting for fixed order
Wasted Employee Genius
Underutilizing people’s talents, skills, & knowledge.
Fast food: Could be improving the kitchen
Every day
Continuously improve.
Make a 2 Second Improvement.
Sort
Sweep
Standardize
3S, the most important activity anyone will ever do to learn lean.
Pull, and one piece flow.
Pull
Customer demand pulls goods
Rather than producing.
One Piece Flow
Focus on one at a time
Rather than making 20 at once. What if there is a defect? All 20 are impacted. Make one at a time.