Phase 1 is an energetic and through provoking introduction to the 7 wastes of lean. Expect a chaotic and noisy production run, untidy workplaces, badly organised workflow, a poor understanding of the customers’ requirements and plenty of identifiable waste!
An example question from the phase 1 review sheet:
Would it have helped if you had discussed business or order processing issues with the customer? If so, what would you want to achieve from these discussions?
Understanding product specifications
Definition of product quality
Dealing with surplus materials
Familiarity with the product, improved workflow and better workplace organisation will improve productivity but there's a huge temptation to increase the levels of work in progress (WIP). What would a finance director think?
An example question from the phase 2 review sheet:
There is likely to have been a lot of waste during phase 2. What was wasted or caused the waste?
Effective location and storage of components
Problems with batch production and high WIP
Communicating with the customer
Kanbans (visual triggers to control production) are introduced in phase 3. Participants should see WIP levels reduce dramatically, communications becoming streamline and a 50% improvement in takt time (time to produce).
An example question from the phase 3 review sheet:
Compare the work load in different areas. How well was it balanced? Were there any bottle necks or slack?
Use of visual displays and pull systems
Benefits of shorter lead times
Process design for market requirements
Overall capacity planning
Work distribution and balance
Participants are given a forecast by the customer so will they maintain their commitment to pull? Watch WIP levels very carefully! Dealing with variation is a key theme in this phase.
If your customer demand quadrupled what are the advantages and disadvantages of: adding more people to existing work stations (and sub-dividing the work) or having several work stations working in parallel?
Alternative forms of Kanbans
One-piece flow and appropriate documentation systems
Coping with variable customer demand
Teamwork and flexibility
Clear definition of responsibilities
Production is re-organised across 3 locations simulating a dispersed supply chain. How well will participants apply their newly learnt lean knowledge?
An example question from the phase 5 review sheet:
How do you think the following could benefit by the effective implementation of the principles introduced in through KanDo lean:
Dealing with remote businesses
Avoiding component shortages
Simplifying the supply of components
Supply chain information flow and constraints