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Lean Thinking Workshop

Participant Guide

Lean Thinking

Workshop


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Table of Contents

INTRODUCTION .......................................................................... 1

MODULE 1: DMAIC ..................................................................... 2

MODULE 2: DMAIC GOALS & ACTIVITIES .......................... 3

MODULE 3: THE TEMPLATE ................................................... 9

TEMPLATE ................................................................................. 10

CONCLUSION ............................................................................. 15

ADDITIONAL RESOURCES ..................................................... 16

WRAP UP QUIZ ......................................................................... 18


1

Introduction Waste occurs throughout our day-to-day lives. Where we work, where we live, where we run errands, it is inevitably occurring all around us. A key missing component is Lean Thinking. In this workshop, we are going to talk about fundamental lean thinking, problem-solving processes, and how it applies in your world today. When you are done, you will:

Be able to identify each stage of the lean problem-solving acronym: DMAIC

Demonstrate broad knowledge of the lean problem-solving methodology

Create a lean problem-solving template that you will take with you

Finally, there is a new way to think about things in business or even in your personal life, a more efficient and effective way.

Lean is simply creating an environment where you have the right amount of resources-where work is paced and content targeted according to customer

demand. More importantly, Lean is having the ability to rapidly respond to a signal from the customer through

a standardized process –which means it is predictable, controllable, and sustainable.”

-Jim Kaminiski, Ass’t VP, Bank One


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MODULE 1: DMAIC OBJECTIVE 1: STUDENT WILL BE ABLE TO IDENTIFY EACH STAGE OF THE LEAN PROBLEM-SOLVING

ACRONYM: DMAIC.

What is DMAIC? DMAIC is an acronym that stands for: Define, Measure, Analyze, Improve, and Control. It’s a five stage process that when used properly, can help to solve problems effectively. This methodology is utilized in lean thinking as well as in Six Sigma. Each area has a specific purpose and usually some regularly used “tools” sometimes statistical in nature, other times just standard problem-solving methods.

When combined together in a systemic process like DMAIC, problems can be identified, measured, analyzed, improved with control features in place to prevent a roll-back. When this occurs, companies of all types can see a true value added to the bottom line. There are many things you need to understand about Lean Thinking, but the most crucial piece to your success is understanding the process and sticking with it.

Brainstorming Think about each area of DMAIC, list activities you think might help you “solve” in each stage:

Define______________________________________________

Measure____________________________________________

Analyze_____________________________________________

Improve_____________________________________________

Control______________________________________________


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MODULE 2: DMAIC GOALS & ACTIVITIES

OBJECTIVE 2: LEARNERS, GIVEN DMAIC STAGE NAMES, WILL DEMONSTRATE BROADER KNOWLEDGE OF THE LEAN

PROBLEM-SOLVING METHODOLOGY BY IDENTIFYING A GOALS AND/OR ACTIVITIES AT EACH STAGE.

What is the DEFINE Phase?

The define phase is the first phase of DMAIC methodology. The

phase identifies the product and/or process to be improved and

ensures that resources are in place for the improvement project.

Essentially, it defines the problem or a potential opportunity for

continuous improvement, in a process or procedure that effects

customer requirements or specifications. Your customer can be

anyone that is explicitly affected, i.e. co-worker, senior

management, vendor, consumer, etc.

Minimally, you should uncover:

For whom are you doing this project?

Who or what functions will realize benefits?

What is the opportunity or need?

Does your company culture support an improvement?

Set expected benefits (dream big and best case scenario) and set an

improvement goal based on critical parameters.

Tools typically utilized to expose this phase:


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What is the MEASURE Phase?

The measure phase is the second phase of the DMAIC

methodology. This is the act of defining and identifying key

measurements and collecting data. This is also known in some

industries as Key Performance Indicators (KPI’s). KPI’s are

applied to measure the success of processes and that presents a

conclusion for a quantified evaluation of any given characteristics

and/or level of operation based on the observed data collected.

During this measure phase you should determine a sampling plan

to meet goals and establish measurement methods and tools, one of

those could be using KPI’s.


Metrics, as-is today and expected.

Documentation of current state and future state, best used via Value

Stream Mapping.

Identify scope of the project, what’s in and what’s not in, who do you

need to help the process?

Present your business case using expected benefits and projected cost

for implementation.



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What is the ANALYZE Phase?

The analyze phase is the third phase of the DMAIC methodology.

Analyzing is the action where a process, procedure, or service

details are examined for improvement opportunities. You do this

by examining the data you collected from the measure phase to

confirm the source of delays, waste and poor quality. From this,

you can generate a prioritized list of the variation sources. This

phase focuses improvement efforts by separating the potential few

variables (those most likely responsible for the variation) from the

trivial many (those least likely responsible for variation).


A prioritized list of potential sources of variations.

Root cause and/or Failure Mode and Effects Analysis (FMEA)

A refined estimate of the financial benefits that may be realized by

improving the process.

Improvement Plan


Note: most of these tools are cause and effect based.


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What is the IMPROVE Phase?

The improve phase is the fourth phase of the DMAIC

methodology. The improve phase defines the solutions will meet or

exceed the quality improvement goals of the project. All actions

are taken to improve the processes as recommended from your

prior phases’ analysis.


Implementation of your improvement plan recommended in the

Analyze phase

Measure improvements

Develop conclusions, recommendations, and next steps



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What is the CONTROL Phase?

The control phase is the fifth and final phase of the DMAIC

methodology. This phase monitors the implementation of the plan

or solution to ensure that the solution is sustained. This is a critical

component and should given great consideration to implement fail-

safe methods to ensure that processes, procedures, services do not

roll back to prior ways of doing business. That is, until and unless

new knowledge and data show there is a better way to operate. Part

of this is ensuring to pass off all learning to the process owner,

including went well and what didn’t.


Making sure the new process is fully documented (and that

documentation is used)

The final financial benefit analysis; validated by the finance

department

Continued verification of gain progress long term

Establishing “out of control” performance indicators



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DEFINE

MEASURE

ANALYZE

IMPROVE

CONTROL

Unscramble and then link these tools to where you might find them

useful. Hint: you may find several “roads” to each stage.

ACCHLNOORRSTT C _ _ _ _ _ _ _ _ _ _ _ S

MSELRAAVUEAPTM _ _ _ U_ _T_ _ _ _ M_ _

ICWMPOM _ _ _ _ W _ _

GNIOMSITBRNAR _ _ _ _ _ S_ _R_ _ _ _

CIARS _ A _ _ _

NALNTEISCLFABFNYIAENASII

_ _ _ _ N _ _ _ _ B _ _ _ _ _ _ _N _ _ Y _ _ _


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MODULE 3: THE TEMPLATE

OBJECTIVE 3: STUDENT WILL DEMONSTRATE COMPREHENSION OF THE DMAIC METHODOLOGY BY CREATING A

TEMPLATE. THE TEMPLATE WILL INCLUDE A SECTION FOR EACH STAGE OF DMAIC ALONG WITH AT LEAST ONE TOOL

AND PROMPTING QUESTION FOR EACH LEVEL.

The DMAIC template is a staple component to allowing you to

follow the systemic process of DMAIC to solve a problem. There

is a reason its five steps and a reason it is in the order it is in.

Trying to work out of process DIMAC will never work.

Furthermore, short cutting stages from the process, as many tend to

do, will only cause continuous waste.

The template is designed to prompt you for things to “uncover”

and ways you can do that. As you complete the template, you can

share it with your company sponsor(s) that have interest in your

improvement process. It is designed for regular updates at each

stage. You will create a very rough outline of a template now from

what you have learned today. This template you will take home

with you so that you can use it. Online there are many versions,

you may wish to customize your very own. There is no right or

wrong way, just as long as you cover each step before moving to

the next step.


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Your Name:

Company Name:

Project Sponsor:

Project Start Date: Estimate Completion Date: Actual Completion Date:

TEMPLATE

STAGE NAME:

Questions/Prompts:

1.

2.

3.

4.

Tools:

1.

2.

3.

4.


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Stage Name:

Questions/Prompts:

1.

2.

3.

4.

Tools:

1.

2.

3.

4.


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Stage Name:

Questions/Prompts:

1.

2.

3.

4.

Tools:

1.

2.

3.

4.


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Stage Name:

Questions/Prompts:

1.

2.

3.

4.

Tools:

1.

2.

3.

4.


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Stage Name:

Questions/Prompts:

1.

2.

3.

4.

Tools:

1.

2.

3.

4.


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Conclusion What you’ve learned here today is a basic introduction to Lean

Thinking by way of DMAIC. If you want to learn more there

are reference texts at the end of this guide for you to read more

about Lean and how it can help your organization.

Be brave! Not all the roads have been paved smooth for you.

There is still much to be learned and you will undoubtedly add

to the existing wealth of knowledge with your own learning

and experimentation as you apply the foundational principles

of “lean thinking.”

Enterprises before you that have adopted lean principles and

practices are transforming themselves into efficient and

relentless developers and you can join them!


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Additional Resources George, M. L. (2003). Lean Six Sigma for

Service. The McGraw Hill Companies.

George, M. L. (2004). The Lean Six Sigma

Pocket Toolbook: A Quick Reference Guide to

100 Tools for Improving Quality and Speed (1

ed.). McGraw-Hill. doi:ISBN-13: 978-

0071441193

Womack, J. P. (2003). Lean Thinking: Banish

Waste and Create Wealth in Your Corporation,

Revised and Updated (2nd ed.). Productivity

Press. doi:ISBN-13: 978-0743249270


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Works Cited

George, M. L. (2003). Lean Six Sigma for Service. The

McGraw Hill Companies.

Polesky Ph.D., D. G. (2012). Lean Six Sigma Process

Improvement Certification. Phoenix, AZ.

Strickland, D. J. (n.d.). LGB Project Template. Phoenix, AZ.

Retrieved 2013


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Wrap Up Quiz

QUESTION 1: Complete the missing information to spell out

each stage of the lean problem-solving acronym, DMAIC:

D___________ M___________ A___________

I____________ C___________

QUESTION 2: Match the associated Define, Measure, Analyze, Improve, Control stage with the its related goals or activities. Write the letter (s) D, M, A, I, C in the preceding space to identify the stage(s) the item would be applicable.

Note: Some items may be applicable to multiple stages of the process.


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____ COMMWIP

____ Root Cause

____ Capture Metrics

____ Value Stream Mapping

____ Future vision

____ Control Charts

____ Current State

____ Implementation Plan

____ Financial Benefit Analysis

____ Brainstorming

____ Flow Charts

____ Project Schedule

____ Identify Solution

____ 5 Why’s

____ Priority Matrix

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