Simply Lean was created to provide the necessary forms and worksheets for a team to learn, implement, and document Lean problem solving activities using the PLAN-DO-CHECK-ACT (PDCA) methodology as an overall approach to learning and implementing process improvements. PDCA is a cycle of activities designed to drive continuous improvement. Initially implemented in manufacturing, it has broad applicability in business. First developed by Walter Shewhart, it was popularized by Dr. W. Edwards Deming. The activities surrounding the implementation of the PDCA methodology will be referred to as a Kaizen Event (see next section). Lean tools and concepts will be briefly referenced where appropriate to assist the overall Lean training process.
Problems (or areas for improvement) can be identified via a current state value stream map, process map, customer mandate, or by negative trends from a Balance Scorecard or some type of performance measurement.
Simply Lean will assist teams and individuals to:
Collect the right data, in the right way, to support Lean or Six Sigma projects
Meet effectively to maximize organizational resources
Brainstorm to solicit best ideas
Obtain a consensus to solve problems and determine solutions
Determine root cause(s)
Standardize improvements
Think outside the box
Accept change
Work to attain process perfection
Simply Lean was designed to be:
A standard problem solving and continuous improvement guide. To ensure the best use of everyone’s time, this guide will provide the basic structure (i.e., standard) for which all Lean or Six Sigma teams should follow (or supplement your existing Lean or problem solving training). By using time wisely, it will reduce the variation in the overall continuous improvement process and provide a solid foundation upon which to introduce Lean tools.
A reference guide for the problem solving and continuous improvement tools. Short, concise definitions of a tool, along with an example, will allow a team member to reference the tool when needed - especially when that team member is away from the team collecting data or working on a pilot project as part of the event.
A learning tool. A case study called “Tinker Town” is presented throughout this book to provide examples of how the various tools are used, as well as their relativity to Lean. This case study will assist you to better understand how to use a particular tool in your project.
An implementation tool. The forms and worksheets have been provided with links to Dropbox Excel files for immediate application and use.
