Progressive Lean: Let's Get Started
OK, after several introductory posts, we're ready to get started laying out the Progressive Lean approach. Here are the five phases:
Strategy and Spread the Word
The Steering Committee is established. That Steering Committee develops a plan and a schedule for rolling out the subsequent phases.
The plan and schedule is communicated to everyone in the plant. Supervisors and team leaders are trained as to how to carry out the Sort and Shine phase.
Sort and Shine
The plant, both shop floor and administrative areas, is divided into areas. Each area has associated with it a team and a team leader who will further divide the areas into smaller locations. The teams will develop and carry out a schedule for sorting and shining those locations.
Straighten and See
Team leaders and supervisors are trained regarding visual controls. The teams develop a new schedule for planning locations for everything in their assigned areas, putting everything in the selected location, and putting the necessary visual controls in place.Implementation of Leader Standard Work begins.
Simplify and Solve
Supervisors and operators learn and participate in value stream mapping, team problem solving (A3, 5P, 8D...whatever), set up time reduction, poka yoke, kanban, heijunka. Teams are established to address operations problems and improvement opportunities.
Standardize and Sustain
Task instructions are developed. TPM protocols are developed and implemented. Systematic operator training and cross-training is implemented. Leader Standard Work is fully implemented.
That's it in a nutshell...a small one. Next time we'll look the whole plan over again and address some possible issues with it.
- Strategy and Spread the Word
- Sort and Shine
- Straighten and See
- Simplify and Solve
- Standardize and Sustain
Strategy and Spread the Word
The Steering Committee is established. That Steering Committee develops a plan and a schedule for rolling out the subsequent phases.
The plan and schedule is communicated to everyone in the plant. Supervisors and team leaders are trained as to how to carry out the Sort and Shine phase.
Sort and Shine
The plant, both shop floor and administrative areas, is divided into areas. Each area has associated with it a team and a team leader who will further divide the areas into smaller locations. The teams will develop and carry out a schedule for sorting and shining those locations.
Straighten and See
Team leaders and supervisors are trained regarding visual controls. The teams develop a new schedule for planning locations for everything in their assigned areas, putting everything in the selected location, and putting the necessary visual controls in place.Implementation of Leader Standard Work begins.
Simplify and Solve
Supervisors and operators learn and participate in value stream mapping, team problem solving (A3, 5P, 8D...whatever), set up time reduction, poka yoke, kanban, heijunka. Teams are established to address operations problems and improvement opportunities.
Standardize and Sustain
Task instructions are developed. TPM protocols are developed and implemented. Systematic operator training and cross-training is implemented. Leader Standard Work is fully implemented.
That's it in a nutshell...a small one. Next time we'll look the whole plan over again and address some possible issues with it.
Posted by George Bohan at Thursday, October 20. 2011 
Categories: How to Implement Lean Manufacturing
Categories: How to Implement Lean Manufacturing
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