Partners in Business Excellence, LLC

lean business coaching

The Value of Lean Training

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Lean Training

One of the resources I offer is Lean Training. Using several Lean tools, we run through simulations several times in order to incorporate new processes to generate huge results. The practices (or tools) can be used in everything from inventory management to streamlining the process of on boarding a new customer. That’s what makes it so powerful to learn- it encompasses continuous learning and allows you to use it in every faucet of business.

What is Lean?

The term “lean production” was invented by James Womack in his book, “The Machine That Changed the World” in order to describe the revolutionary process created by the Toyota Production System. Used primarily in mass production concepts, it is a system designed to eliminate wasteful practices. Lean Management then is the journey, as you never ‘arrive’ or complete continuous improvement, of managing with the Lean tools in mind.

What does Lean Training include?

In Lean Training sessions we teach several of the tools to help organize and streamline business processes to be more efficient. After classroom training, facilitated hands on implementation is conducted to ensure that the skill has been learned and can be used.  Some of the tools you will learn about include, but are not limited to:

5S: this tool allows us to organize through 5 steps, namely: Sort, Set in Order, Shine, Standardize and Sustain, and in some cases we also add a 6th S for Safety.

Cellular Flow: A system structure that increases accountability, efficiency and quality by having teams work together rather than be departmentalized.

Standardized Work Flow: Systemizing and standardizing work processes is critical in reducing waste. We discover where someone is duplicating a process or doing it differently than others, or where no business process exists and create or modify it.

Continuous Flow: This process helps us find areas of non-value added time and reduce it.

5 Whys: This Lean tool helps you to get to the root cause of problems so they can be addressed with true, long-lasting fixes rather than “band-aid” ones.

A3 Problem Solving Method: Your Lean Training will teach you how to solve any problem that arises with more ease. Systematic problem-solving done on a single piece of paper allows you to cut to the solution faster than ever.

 

As a practitioner and educator of Lean for many years and a TWI Certified Trainer, we will not only work through the specific challenges in the business, I will teach you how to continue to improve with the Lean tools. As your “Lean Sensei”, I use these non-software based solutions that can be implemented quickly and easily to reach the goals you are desiring.

Contact me today to learn more about how lean manufacturing can simplify and improve your business processes making them easier to understand, perform and manage. Together, we will create a continuous improvement culture and healthier bottom line.

Dealing with a Frankenstein Business Process? What It Is and How to Fix It

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I have the privilege of working with forward thinking businesses. These businesses know something isn’t quite right, but they can’t always put their finger on it. I’m called in and using a variety of techniques, discover and correct workflow holes and implement process improvement.

Birth of a Process

The first time that a series of steps are performed to complete a task, a process has been born. I use the word “born”, instead of developed, as rarely are processes designed. A business process exists because someone saw the need for something to get done. All of our daily activities are conducted through processes, some are good and some are poor. We recognize the poor processes typically through things that frustrate us. For example, standing in line for hours waiting for a representative to take five minutes of their time to explain the many pages of forms required to fill out. Poor processes can be the state they are in due to something I call a Frankenstein Business Process.

Typical Development of a Business Process

Most processes change many times. They may change in response to changes in technology, changes in products or services and/or changes in customer requirements.  Most often, however, a business process changes for various other reasons, not always in a way best for a business.

One of my responsibilities when working with a business is to ask why they do things the way they do. The typical response is that no one knows why and that it is how they have always done it. One business I was called into found themselves in a state of panic and urgency because the company they relied on for their envelopes had gone out of business. It was an important part of their workflow and they weren’t sure how to manage the change.

It turned out that the specialty envelopes were ordered once because the standard ones were not available, and they continued to order believing there was a requirement for them when there really wasn’t. On the surface, this may seem to be a small issue, but it really created a great deal of problems as a new vendor couldn’t be identified and it was effecting their production to not have this particular and critical supply.

In this case it was envelopes, but in another scenario, it could be a change in adhesive, for example, that effects the final product output. This, in turn could also affect price, skills needed, equipment changes and more.

The Frankenstein Process

Over time, business processes will naturally change. We hire new employees with a mix of education and experiences who change the processes to try to make them better, or in response to poor performance of the business. These changes become a “Frankenstein” process, that is, steps have been added or removed without really looking at how the process works overall. Processes like these are ingrained with wasteful, frustrating and unproductive steps that end up costing a business money, or worse yet, employees or customers.

I believe it doesn’t matter how great your product or service is, your business is only as good as its processes.

Innovation’s Opposite

The biggest curse to innovation is that of “We’ve always done it that way”. When we really look at the need, regardless of how things were done before and independent of the fixes that were put into place, we can discover waste and inefficiencies and replace them with new, improved processes that are long-lasting, rather than quick, Frankenstein fixes that eventually fail.

Contact me today to learn more about how I help businesses to simplify and improve their business process making them easier to understand, perform and manage. Together, we will create a continuous improvement culture and healthier bottom line.