Lean techniques - BPTrends March 2007 Lean Tools That Improve Processes Lean Tools That Improve Processes An Overview Forrest W Breyfogle III Lean

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1 BPTrends March 2007 Lean Tools That Improve Processes Copyright © 2007 Forrest Breyfogle. All Rights Reserved. www.bptrends.com Lean Tools That Improve Processes: An Overview Forrest W. Breyfogle III Lean emphasizes the learning by doing approach, where the members of a process improvement team are those most closely associated with adding value to the product. The whole process is based on defining customer value, focusing on the value stream, making value flow, and letting customers determine the product or service they want, with a relentless pursuit of perfection in a timely manner at an appropriate price. We identify the value stream as a process, or series of steps, from concept to launch to production, and then the order to delivery and the disposition; in other words, from the raw materials to delivery of the finished product to the customer. Value stream steps can be value- added, non-value added, or non-value-added-but-necessary. Lean emphasizes the elimination or reduction of steps that do not have value. We start with the customer’s request, strive for no interruptions or waste, avoid batch processing, and strive for smooth just-in-time one-piece flow. An experienced teacher who uses the Socratic method of learning – a dialog of simple questions that leads to an agreed-to solution, facilitates the Lean process. This article presents an overview of 11 tools that have been shown to be productive for Lean initiatives. These methods can be used in the Improve phase of the Six Sigma DMAIC roadmap (Define, Measure, Analyze, Improve, Control). These techniques are also applicable within Integrated Enterprise Excellence (IEE), the performance measurement and improvement process that orchestrates employee day-to-day activities so they align with true business needs. These are the tools: One-Piece Flow One-piece flow describes the sequence of product or of transactional activities (e.g., insurance claims) through a process one unit at a time. In contrast, batch processing creates a large number of products or works on a large number of transactions at one time – sending them together as a group through each operational step. In one-piece flow, focus is on the product or on the transactional process, rather than on the waiting, transporting, and storage of either. One-piece flow methods need short changeover times and are conducive to a pull system. One-piece flow advantages are Reduced customer order to shipment times Reduction of work in progress Early detection of defects Increased flexibility for customer product/transactional demands Reduced operating costs through exposure/elimination of non-value-added waste A project process improvement could be a work flow change that reduces batch size or changes from batch processing to single-piece flow. Poka-Yoke (Error Proofing)
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This note was uploaded on 02/20/2012 for the course MIST 5750 taught by Professor Bostrom during the Spring '09 term at University of Georgia Athens.

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Lean techniques - BPTrends March 2007 Lean Tools That Improve Processes Lean Tools That Improve Processes An Overview Forrest W Breyfogle III Lean

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