Features

Lean helps save lives in South Africa

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    string(1608) "Lean thinking may have been born in Toyota in the 1950s and 1960s, but it wasn’t until after the year 2000 that a few hospitals began to explore its application to the healthcare industry (lean healthcare). These pioneering organizations came together to share their stories at the first Global Lean Healthcare Summit in the UK in 2007, which in turn triggered many more experiments around the world. Since then, interest has kept growing.

Some fifteen years on, we have hundreds of examples to learn from, from clinics and departments through to entire hospitals and even whole hospital systems. Not all early experiments succeeded, and we are still a long way from making lean a widely recognized way of working across the industry.
Healthcare providers around the world still face huge challenges, as ageing populations and unhealthy lifestyles boost the demand for healthcare faster than the growth of incomes and tax revenues from the middle classes. At the same time, the quality of care has not improved as much as the quality of other services in the economy, which is why more and more healthcare organizations are turning to lean.

Historically, lean healthcare ideas have been applied in large hospitals, but in the past few years we have started to see the philosophy adopted in earnest in many smaller organizations following a do-it-yourself approach that has generated many positive benefits. An impressive example is the Consorci Sanitari del Garraf near Barcelona."
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FeaturesOct 10, 2019
Rose Heathcote
FEATURE – Only when we go where the action is, do we begin to truly understand the work. Rose Heathcote joins the Emergency Medical Services in Cape Town for a day.

Our gemba walks in Brazil

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FeaturesOct 7, 2019
Roberto Priolo
FEATURE – Last month, the Lean Global Network met in Brazil for its annual meeting. As part of it, we visited several amazing gembas. Three of our lean coaches reflect on what we learned.

Slashing onboarding time for new developers

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    string(1476) "Improvement methodologies have been used in the software world for a very long time, with approaches like Agile and Lean digital methodology playing a key role in speeding up the development of digital products. Agile principles and ideas - like Scrum and its way of structuring teams and organizing the work - have found their ways into many a lean company. Lean digital thinking and the Toyota Production System, in turn, have greatly influenced the development of these approaches.

Lean Digital is the methodology by which companies apply lean principles to the development process of new digital products.

The world of startups and entrepreneurship has also drawn a lot of inspiration from lean management. Eric Ries' best-selling book The Lean Startup offers a framework for quick experimentation and validation of learning that is often viewed as an interpretation of lean's PDCA cycle - and the very idea of involving the customer at different stages of the process clearly reminds of the fundamental lean idea of listening to the Voice of the Customer.

Despite this great level of cross-contamination, however, a disconnect still exists between the world of 'traditional lean' and that of young, digital companies. A few pioneering organizations such as softrware company Theodo are trying to bridge that gap by solidly applying lean thinking to their digital work. This is a new frontier for lean thinking."
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FeaturesSep 30, 2019
Clément Hannicq
BUILDING BRIDGES – Using kaizen, a team at Theodo was able to reduce the time necessary to install a project on a new developer’s computer from three weeks to twelve minutes.

What is an Obeya?

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FeaturesSep 26, 2019
Roberto Priolo
FEATURE – In this roundup, we discuss the obeya room and use some of the best articles on the topic to explain why it’s such a powerful tool to drive improvement in your organization.

When lean takes off

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    string(1637) "While lean government and lean healthcare technically fall under this category, we consider lean service organizations to be those operating in areas like call centers, retail, hotels, restaurants, offices, banking, and so on. In such environments, there is a direct interaction with the customer, which should be seen as an opportunity to get real-time feedback on our service rather than a nuisance we have to deal with (if you have ever spoken with a customer care representative, you know what this means).

A common problem that practitioners trying to bring lean to services encounter is the difficulty to identify “the work” – whereas in manufacturing the product is in front of everyone’s eyes, in service organizations it is often hidden behind paperwork or a computer screen. Once the work is clearly visible, however, the opportunities for improvement are plentiful. To date, we have seen thousands of organizations striving to lean out the service they provide customers: from restaurants chains in the United States and China to a group of bakeries in Barcelona, from call centers to hotels, the application of lean services ideas can have an extraordinary impact on our economies. Especially if we consider that the service industry accounts for more than three-fifths of the global GDP and employs more than one-third of the global workforce.

Lean thinking is naturally a fit for the service industry, because of its focus on constantly delighting customers and on providing them with value-adding products."
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FeaturesSep 12, 2019
Catherine Chabiron
NOTES FROM THE GEMBA – The author visits the Parisian airport of Orly to learn about a pilot project (pun intended) that aims to tackle the late departure of flights using lean thinking.

What is lean learning?

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FeaturesSep 9, 2019
Tony Lamberton
FEATURE – How does lean apply to learning? The author reflects on the lean transformation his schools are undergoing and on its practical implications on students, staff and leaders.

Turn the beat around

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FeaturesSep 3, 2019
Sharon Visser
FEATURE – One year ago, the author started coaching organizations in her town of Maun, Botswana. Here she reflects on her experience and draws an interesting parallel between lean management and dancing.

Where are we in lean product development?

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    string(1553) "This is another new frontier for lean thinking, not because lean efforts in engineering have only begun recently but because it wasn’t until the last few years that a systematic attempt to codify these techniques has been made. These techniques and ideas are loosely brought together under the concept of Lean Product and Process Development (LPPD).

At a time when innovation is the biggest factor behind the success or failure of an organization, finding ways to speed up the development of new products and to ensure these products correspond to actual customer needs is of the utmost importance.

At its core, Lean Product and Process Development aims to create the exact product that people want. And it is clear that developing better products reaching the market faster means profitability into the future. In general terms, lean product development achieves this by creating reusable knowledge that can be used in future iterations of a product and by deployment set-based concurrent engineering (which entails considering sets of designs at once to quickly eliminate inferior solutions, thus shortening development times). It is also useful to integrate the work of engineers with that of the manufacturing department, so that shop floor receives a well-researched, mistake-proof product that is ready for production without the need for extensive and expensive rework.

Interesting contamination exists here with improvement approaches like Lean Startup and Design for Manufacturing."
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FeaturesSep 2, 2019
The LGN LPPD Team
FEATURE – The authors discuss some of the most common problems that product development teams experience and what an effective assessment tool for engineering looks like.

Lean is an educational system

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    string(1378) "The idea of “lean management” can refer to both individual managerial behaviors and, more in general, the set of principles and practices characterizing the adoption of lean thinking in an organization.

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In its more general meaning, lean management – or lean thinking, if you prefer – derives from the Toyota Production System and is now recognized as a superior management approach that, through continuous improvement, customer focus, teamwork and relentless people engagement, leads to great results in terms of quality, performance, delivery, and cost. The promise of lean management is to create the most value for customers using the least possible amount of resources. As an approach to running a business, it brings benefits to all parties involved, from customers to employees, suppliers to wider society.

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FeaturesAug 27, 2019
Sandrine Olivencia
FEATURE – In this compelling read, the author discusses lean thinking as a system for learning that challenges our assumptions and tells us why blindly applying “best practices” takes us nowhere.

What is 5S?

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FeaturesAug 22, 2019
Roberto Priolo
FEATURE – In this roundup, we look at one of the most important lean tools and how it is deployed in organizations by bringing together PL articles on the subject.

Understanding lean visual management tools

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FeaturesAug 20, 2019
Severino Abad
THE NAKED GEMBA – This useful article helps us to understand the different type of visual controls we can put in place, how they work and which ones to use to best convey our message.

The role of a lean educator

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FeaturesAug 8, 2019
Monica Rossi
FEATURE – What does it really mean to teach lean? The author reflects on this question and shares a few tips on how to successfully engage learners in different environments. 

A sense of heritage in an uncertain world

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    string(1594) "Manufacturing is where the lean movement originated from. For their MIT research in the late 1980s (which resulted in the 1990 seminal book The Machine the Changed the World), Jim Womack and Dan Jones identified a set of principles and techniques that made Japanese carmakers far more productive than their Western competitors.

The superiority of the Toyota Production System is now a recognized fact (Toyota has been profitable every year but one, for half a century), which means that today most manufacturing organizations around the world practice lean manufacturing thinking to some extent. The prevalence of this alternative way of thinking and managing in the manufacturing sector often generates confusion in other industries, in which people’s first reaction to improvement attempts is the now proverbial “We don’t make cars. Lean is a manufacturing thing.”

When applied to manufacturing, lean tools like heijunka, SMED or Kanban cards allow for the optimization of production processes and the systematic elimination of waste (in its three incarnations of muda, muri and mura – respectively, non-value-adding work, overburden and unevenness). These happen by implementing the fundamental lean principles of pull and flow. However, it has now been proved that the principles characterizing lean manufacturing are universally applicable. They work in any sector and they apply to any kind of work – even though at times they require some adjustment."
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FeaturesJul 30, 2019
Catherine Chabiron
FEATURE – In a market where products become obsolete very fast, this Toyota supplier has learned the importance of staying true to its heritage and developing know-how and people’s capabilities.

The synergies you need to succeed

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In its more general meaning, lean management – or lean thinking, if you prefer – derives from the Toyota Production System and is now recognized as a superior management approach that, through continuous improvement, customer focus, teamwork and relentless people engagement, leads to great results in terms of quality, performance, delivery, and cost. The promise of lean management is to create the most value for customers using the least possible amount of resources. As an approach to running a business, it brings benefits to all parties involved, from customers to employees, suppliers to wider society.

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FeaturesJul 11, 2019
Karen Gaudet
FEATURE – While at Starbucks, the author learned the importance of collaboration among the key functions of Operations, HR and Finance to advance a lean transformation.

Introducing the Toyota Flow System

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FeaturesJul 9, 2019
Nigel Thurlow, John R. Turner and Brian Rivera
FEATURE – In the age of complexity and disruption, flowing value to customers as quickly as possible is critical. The new Toyota Flow System strives to address this issue. 

My father is my sensei

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FeaturesJul 4, 2019
Michael Ballé
FEATURE – In this intimate account, the author reflects on the role of a lean sensei by looking back at what he’s learned from his own… his father.

Fertile ground for lean seeds

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FeaturesJun 25, 2019
José Ferro, Ricardo Itikawa and Bruno Battaglia
FEATURE – Lean Institute Brasil is running pioneering lean experiments in agriculture. The authors reflect on the challenges of transforming traditional farming culture and the opportunities lean affords.

Lean learning, learning lean

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FeaturesJun 13, 2019
Dave Brunt
FEATURE – What can the world of lean and the world of education learn from one another? The author reflects on the synergies between these two realities.