1. De-Mystifying Lean De-Mystifying Lean Lean Management Institute of India 1 By Dhirendra Kumar Dubey 2. About Myself 1985: Mechanical Engineering 1985-95 Factory Experience 1995- till date Consulting in Diversified Fields Mentored by Lean SenseiJim Womack pioneers in Lean Management Original Creation of Simple, Understandable and Doable Lean Knowledge De-Mystifying Lean Lean Management Institute of India 2 3. Measures to Deploy our Mission De-Mystifying Lean Lean Management Institute of India 3 4. De-Mystifying Lean Lean Management Institute of India 4 Lean Thinking & Practice (our understanding) Systemically develop people who continuously improve their work and processes creating value for their customers & prosperity for their organisation through driving waste out of the system 5. Shrinking Life Span of Companies De-Mystifying Lean Lean Management Institute of India 5 6. The Lean Fundamentals De-Mystifying Lean Lean Management Institute of India 6 About 7. Lean: Key Things Done by All Levels De-Mystifying Lean Lean Management Institute of India 7 Front Line Team Working on Products & Services Middle Management Top Management Solving problems: To reach the desired base level performance consistently 8. Engine that Drives the Lean De-Mystifying Lean Lean Management Institute of India 8 9. De-Mystifying Lean Lean Management Institute of India 9 Sustained High Performance Business Level Value Stream Level Group & Individual Level Highly motivated people Lean Leadership at All Levels 10. Prevailing Leadership Paradigm: IMeYou De-Mystifying Lean Lean Management Institute of India 10 11. We Need to Move to De-Mystifying Lean Lean Management Institute of India 11 12. Engine that Drives the Lean De-Mystifying Lean Lean Management Institute of India 12 13. De-Mystifying Lean Lean Management Institute of India 13 14. De-Mystifying Lean Lean Management Institute of India 14 Jumping to solutions ! BUSINESS PROBLEM ! Real Problem clarify the problem break down the problem Point of cause find the root cause(s) Take countermeasures Evaluate Standardize PLAN DO CHECK ACT 15. Focus on Waste for Large Gains De-Mystifying Lean Lean Management Institute of India 15 Value Added 5% Incidentals with Current technology or methods 30% Avoidable Non Value Added 65% Optimize Traditional Focus Lean Focus 16. All Systems Consists of: De-Mystifying Lean Lean Management Institute of India 16 17. De-Mystifying Lean Lean Management Institute of India 17 Customer Critical Customer Requirement Call to Notification Time < 5 Days Call Arrival Rate: 350 Customers Per Day Receive Call & Assign Sales Rep. Collect Info & Complete Application Review Application Check Credit and Approve Approve Loan 1X Daily Loan App Management System Work Flow Doc Prep Real Time Updates 1 D 2 D 1 D 2 D 1 D P/T= 3 Min %C/A= 97 % D/T= 10 Min Lost Call = 5% P/T= 52 Min %C/A= 99 % D/T= 25 Min Return = 6% P/T= 30 Min %C/A= 98 % D/T= 38 Min Decline = 8% P/T= 20 Min %C/A= 94 % D/T= 60 Min No Reply= 2% P/T= 42 Min %C/A= 90 % D/T= 70 Min Clarify = 2 % P/T= 50 Min %C/A= 96 % D/T= 0.5 Day Clarify =10 % 3 M 20 M 10 Min 52 M 1D + 60 M 30 M 2D + 25 M 42 M 1D + 38 M 50 M 2D + 70 M 1D +0.5 D L/T= 7.8 Days P/T= 197 Min %C/A= 76.5% VSM-Off Shore Loan Management Process 18. Management Task To Align the Purpose, Process & People De-Mystifying Lean Lean Management Institute of India 18 19. Too Much Focus of People De-Mystifying Lean Lean Management Institute of India 19 20. Too Much Focus on Process De-Mystifying Lean Lean Management Institute of India 20 21. People & Process Balanced by Management De-Mystifying Lean Lean Management Institute of India 21 22. Lean Process Design De-Mystifying Lean Lean Management Institute of India 22 23. The 5 Dimensions for Lean Transformation De-Mystifying Lean Lean Management Institute of India 23 WHAT is our PURPOSE? What situational problem do we need to address? How to develop the people? How to improve the work? Leader behavior & management system? What is our BASIC THINKING? 24. The 4 Essentials for Lean Transformation De-Mystifying Lean Lean Management Institute of India 24 Design and support processes that provide value to customers- value streams Develop people to take personal responsibility for solving problems A3 Mgmt. Set alignment around the Purpose - Hoshin Create the environment for effective problem solving Leaders as a Coach 25. De-Mystifying Lean Lean Management Institute of India 25 26. QUESTIONS? De-Mystifying Lean Lean Management Institute of India 26 Thanks For Kind Attention