Lean

Tools of Lean

Ferguson and Associates follows a Lean Implementation Roadmap to provide a structured implementation.  This six step model provides direction and also establishes the goals and objectives of the implementation.  We will always ask; "What is the business case for this initiative?" 

Lean Implementation Roadmap 

Step	1)  Establish Metrics / Goals	2)  Select Target Area	3)  Identify Implementation Team	4)  Establish Baseline	5)  Plan	6)  Implement
Action	Why Lean: ·    Reduce cycle times ·    Reduce setup times ·    Improve quality ·    Reduce inventory     ·  WIP     · Raw	Items to consider: ·    High probability of success ·    High ROI	Team configuration: ·    NWT ·    Cross functional	Capture current performance: ·    Metrics ·    Photo ·    Video	Develop: ·    Action Plan ·    Implementation Plan ·    Communication Plan ·    Training plan	Implementation steps: ·    Communicate plan ·    Train ·    Monitor / post results ·    Review status ·    Revise Goal ·    Start Over
Tools	Charts	·    Pareto Chart ·    Stat. Anal. ·    Critical Path ·    VSM	Team configuration: ·    NWT ·    Cross functional	·    VSM ·    Flow Chart ·    Critical Path ·    SMED Application	·    VSM ·    Process flow analysis ·    Future state map	·    Future State VSM ·    Kaizen ·    Kaizen Blitz
Metrics	·    Cost    ·    Inv. Turns     ·    Inv. Value     ·    Scrap     ·    Rework ·    Time ·    Supplier Rating ·    Reduce work space		·    Team maturity matrix ·    Team readiness survey	·   Cost    ·    Inv. Turns          Inv. Value    ·    Scrap    ·    Rework ·   Time ·   Supplier Rating ·   Reduce work space		·    Cost    ·    Inv. Turns     ·    Inv. Value     ·    Scrap     ·    Rework ·    Time ·    Supplier Rating ·    Reduce work space

Lean Frequently Asked Questions

Doug Answers FAQ’s

Q.  What is World Class?

A.  Being better than every other company in your industry in at least one important aspect of your operation.

Q.  What do you feel is the most important to customers?

A.  The same that is important to us as consumers, cost, quality, and having the item available when you want it.  Organizations that develop the ability to mass produce in lots-of-one are the organizations of the future.

Q.  What is Lean Manufacturing?

A.  Lean manufacturing is a dynamic continuous improvement environment based on speed, through the removal of non-value added activity.  Speed to market, fast cycle times, and rapid customer response, to create a new paradigm for business success.

Q.  What are some of the measurements for a lean organization?

A.  Return on assets, on-time delivery, cycle time, supplier order fulfillment, inventory turns, cash-to-cash, quality, operations per operator, and WIP are just a sampling of the ways to measure the effectiveness of a lean organization. 

Q.  Does lean only affect the shop floor operations?

A.  Practicing lean as a way of business involves all areas and all departments to actively participate.  Implementing lean throughout the entire organization creates an organization dedicated to continuous improvement to meet customer demands for quality, price, and delivery.

Q.  What is a value added activity?

A.  Any activity that the customer is willing to pay for.  Any activity that does not add value, adds cost, e.g., over-production, set-up, and storage are examples of non-value added activity.

Q.  What is a Kaizen Blitz?

A.  A Kaizen Blitz is an event to rapidly change a process for maximization of resources.  The event is usually a 2-5 days process that reduces cycle time, reduces WIP, and minimizes non-value added activity. 

Q.  What are the rules of a Blitz event?

A.  Very basic, there are only four rules;

1. Safety will never be compromised

2. There will always be a recovery plan

3. Everyone who is affected by the Blitz will be involved in the process

4. The Blitz will not impact the customer in a negative way? 

These are the rules for every event.