Lean process improvement is defined as a system used for eliminating waste and improving systems within a business. Car manufacturer, Toyota, developed this concept to help with their production operation and cut down the time it was taking to receive an order.
When using a lean approach, waste is minimised, and more value is provided to the customer. You will be delivering what the customer needs when they need it, reducing inventory, increasing productivity, improving quality, increasing satisfaction, reducing your overall costs, and increasing your profits.
To put it simply, lean methodology is a way for you to optimise the people, effort, resources, and energy of your organisation and create more value for your customer. The two main things to focus on, however, is continuous improvement and respect for people.
More About Lean Process Improvement and The Tools Needed
Kaizen is a method of continuous improvement where all employees at all levels of a company work as one to achieve incremental improvements and enhance the manufacturing process. Utilising this method often results in efficiency savings and allows organisations to reduce process waste while adding value at the same time.
The 8 Wastes involved in lean process improvement are:
- Defects
- Overproduction
- Waiting
- Inventory
- Motion
- Non-utilised talent
- Transportation
- Excess processing
Problem solving is a huge part of lean process improvement. Lean problem solving is defined as a way of approaching organisational problems as you aim for continuous improvement and use proven, problem solving methodologies. Your goals will be to use data and process flow to focus on and improve a problem that you are facing.
Process mapping, for example, is one of the top-level tools of Lean process improvement. This tool can identify the areas and steps required for improvement within an organisation by working in harmony with the other tools of lean manufacturing. For example, another useful tool is ‘the 5 Whys.
The 5 Whys
The 5 whys are essentially five principles which are considered a recipe for improving workplace efficiency. These include:
- Defining value
- Mapping the value stream
- Creating flow
- Using a pull system
- Pursuing perfection
Fishbone Analysis
Another easy lean methodology to use is the fishbone analysis/diagram, also commonly referred to as an Ishikawa or cause-and-effect diagram. This is a simple method and can help a team to discover potential causes of issues and can be used in combination with brainstorming processes.
There are many instances in which lean process improvement and its tool kit can be utilised. For example, lean manufacturing and the development of physical products. Lean in the service sector enables reduction of unnecessary activities such as the number of call transfers and unnecessary IT processes, whilst also providing solutions to cut down on errors. Lean in hospitals minimises waste and maximises patient care, allowing organisations to become more patient-centered.
During my next few blog articles, I will be exploring the tools and subsequently how they can help focus on improvements across organisations.
