Lean Help
Lean or the
lean enterprise is a term coined by Jim Womack to describe the Toyota
Production System. Scanlon's ideas were studied by the Japanese
who combined them with the ideas of W. Edwards Deming. Today many
business leaders are studying Japanese management techniques without
knowing Scanlon's contribution.
Scanlon Companies in turn have
studied Toyota and have produced two Lean tools that are used worldwide
to teach and to implement lean concepts.
- Lean Sim Machine:
A comprehensive hands-on manufacturing simulation designed to teach front-line workers the fundamentals of Lean Manufacturing.
- Hoshin Quick Start:
An integrated training program and computer software designed to teach Hoshin concepts and to track and analyze plans.
Both
tools were developed by the Magna Donnelly Corporation and further
enhanced by the Scanlon Leadership Network. The tools help to
contribute to the following results at Donnelly:
- 35% reduction in scrap
- 30% improvement in productivity
- 90% reduction in customer defects
What Others Say About the Lean Sim. Machine:"
A very realistic, down to earth simulation. A great teaching and
learning tool! The Lean Sim. Machine clearly demonstrates the
differences between traditional and competitive manufacturing systems.
The discussions and "team build" problem solving techniques that were
presented in between each production simulation encouraged involvement
and interaction from all participants."
General Motors, Lansing Training Division
"The
Lean Simulation is an important teaching tool at Donnelly. Rather than
lecture at people, the simulation allows participants to experience how
their decisions impact the bottom line in a much more powerful and fun
way. We require all new hires to experience the simulation. We also use
it for team facilitators to teach our policy deployments system. An
advanced version is used to teach how a total pull system works. The
simulation provides any facilitator with a flexible tool to not only
teach lean concepts, but to show how leadership, participation, and
teamwork work. Our employees like how the simulation recreates the
dynamics of a real factory."
Jay Ewing, Manager, Donnelly Production System Office
"The
Lean Sim. Machine is an extremely effective way to educate all levels
of the organization on lean manufacturing principles and how they tie
into financial performance. I recommend it to anyone launching lean
manufacturing efforts."
Steven J. Kay, CPA, Plant Manager, Spring Engineering and Manufacturing Company
"The
Lean Manufacturing Simulation is one of our most effective training
tools. Our employees easily associate the simulation with our
manufacturing process and product structure. The conversion from a
conventional, functional department structure to an efficient lean
manufacturing process is very convincing. It allows employees to tie
together how moving to a lean manufacturing process on the shop floor
can impact the bottom line."
Randy Boonstra, Director of Stamping/Forming, National Manufacturing Company
"This
simulation is a great way for people to learn experientially how to
create economic growth and ship quickly with a lot less inventory."
Rob Sligh, President, Sligh Furniture Company
"The
Lean Manufacturing Simulation is one of the most exciting learning
tools I have seen. It allows people to stimulate lean concepts without
creating real scrap or losing customer goodwill. It took over three
years to develop. The Participant and Leader Guide were designed by one
of the Instructional Designers in the country."
Paul Davis, President, Scanlon Leadership Network
Solid Theory and Practice:
The
Lean Sim Machine is based on the Harvard Business Review article
"Decoding the DNA of the Toyota Production System" by Steven Spear and
H. Kent Bowen (Reprint 99509).
The Simulation was over three
years in development at Magna Donnelly. It received a Gold Medal "Best
Practice" award from the Network and was then released to the
membership. It was further refined and one of the nation's foremost
instructional designers was hired to create the Leader's Guide and
Participant Manual.
Organizations using the Lean Sim Machine:
-
National Manufacturing
-
Magna-Donnelly
-
Sligh
-
Michigan Manufacturer's Technology Center
-
General Motors
-
Bridgestone/Firestone
-
Westling Manufacturing
-
Nicholas Plastics
-
Spring Engineering and Manufacturing
-
The Right Place
-
Competitive Edge Associates
- Ferro
- Spartan Manufacturing
- ITT Industries
- SGS Tool Company
- Wescast
- Westan
- S & L Plastics
- Meier Tool and Engineering
- The Right Place
- Lansing Community College
How the Lean Sim. Machine Works:
Objective:
The Lean Sim. Machine allows six to ten people to experience
traditional and lean manufacturing concepts in eight hours.
Method:
Highly interactive and hands-on, the Lean Sim. Machine allows
participants to create the dynamics of a factory that produces
automotive components. Processes created include: injection molding,
heat treating, painting, assembly, and conveying. Three product
variations require die-changes and quality defects can be introduced by
the facilitator. The simulation begins with traditional manufacturing
and moves to Lean as participants suggest changes that can be
immediately tested.
Outcome: Participants see the immediate
impact of Lean Manufacturing techniques on the bottom line and learn
how to work in a team. Click here to download the 25 page PDF
simulation overview from the Leader Guide, which describes the
conceptual foundation, the background, variations, recommendations and
description of the simulation, as well as references for lean thinking.
Click
here to download the 25 page PDF simulation overview from the Leader
Guide, which describes the conceptual foundation, the background,
variations, recommendations and description of the simulation, as well
as references for lean thinking.
 overview 668.88 Kb
Click here to download the Lean Sim. Machine™ brochure as a pdf file.
lean_sim 315.47 Kb
A Turnkey Factory in a Box Training Solution:
More than paper and pencil, Legosª or TinkerToysª Your factory-in-a-box includes:
-
3 Finely Crafted Oak Machines that simulate typical manufacturing processes
-
a paint line (includes paint racks, paint booth, conveyor system and ramps)
-
an injection molding machine (complete with 3 dies to simulate die changes)
-
a bolt hardening machine
-
Comprehensive Leader Guide with Overheads and Class Handouts (over 150 pages)
-
30 Page Reproducible Participant Manual
-
Excel Spreadsheet to Automatically Perform Financial Calculations
-
Pallets, Finished Good Racks, Nuts, Bolts, Linkages
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Heavy Duty Locking Storage Box
The Heat Treating Machine
The Paint Line
The Injection Molding Machine
Flexible Use Options:
- Purchase the Machine and rights to reproduce the Participant Manual
- $5900 for NonNetwork Organizations
- $2900 for Network Members
- Rent the Machine for five working days
- $900 for NonNetwork Organizations
- Free (except for shipping for Network Members
- Hire the Scanlon Leadership Network to present the program at your location (Contact the Network for a quote)
Hoshin Quick Startv3™
Hoshin
Kanri is a Japanese word that cannot be directly translated into
English, but it implies a direction needle or compass or managing
direction. A popular translation is policy deployment. Hoshin is a way
to get everyone in an organization pointed in the same direction. It
starts at the top with strategic planning and it works its way through
the entire organization, so that everyone knows what they need to do to
help the organization meet its goals. Hoshin requires progress toward
goals to be tracked and interventions made when goals are not being met.
Hoshin can produce tremendous results. Texas Instruments reported the following:
- 70% reduction in customer returns
- 60% reduction in manufacturing cycle times
- 75% reduction in missed deliveries
- 65% reduction in product defect levels in two years
Researchers
have found organizations that use Hoshin have s higher return on assets
(8% compared to 4.5%) a higher return on Equity (10.2% compared to
4.4%) and a higher shareholder return (7.9% compared to 0%)..
According
to James Womak of the Lean Enterprise Institute the lack of Policy
Deployment (Hoshin) is the root cause of most lean implementation
failures.
Hoshin
Quick Startv3™ contains a completely redesigned Leader Guide and
Participant Manual to include the latest research on the five alignments
of Hoshin.
What others say about Hoshin Quick Startv3™
Hoshin
planning represents a very powerful tool for deploying the strategic
direction of any organization. It not only ensures that everyone in an
organization understands the strategic direction but it also ensures
that they understand how their work and the work of other teams within
the organization fits together. It is also a powerful tool for bringing
out the best in everyone through participation."
Dwane Baumgardner
CEO
Donnelly Corporation
Hoshin
Quick Start™ improves organizational performance by providing efficient
way to document, track, and share objectives. When everyone is pointed
in the same direction , and is accountable results happen. Since
objectives are tracked on an ongoing basis there are no surprises.
Paul Davis
President
Scanlon Leadership Network
SGS has customized Hoshin Planning all the way to the acronym,
Associate Integrated Management (AIM 2001). It has provided us with an
excellent communication tool to present our company's goals and
objectives while documenting a ones of accountability for ALL
associates."
Tom Hagg
President
SGS Tool Company
I
have worked with Hoshin Planning for several years with great success.
Hoshin Quick Start™ provides the level I have been missing by
automating the process.
Consultant
Hoshin Quick Sart™ helps to ensure the strategic plan gets implemented and doesn't sit on a shelf in a three-ring binder
Pete Hovde
The Possibility Company
The
use of Hoshin (we call our plan AIM 2001)at SGS has made a significant
improvement. AIM (Associate Integrated Management) has enabled all
Managers to see exactly how their department Goals and Objectives
support the SGS Corporate Objectives. Simply put, AIM 2001 gives us a
"Road Map" and navigates us on our journey.
Jeff Burton
Executive Vice President of Manufacturing
SGS Tool Company
Hoshin Quick Start is a total solution containing three parts:
A 4 hour Hoshin training course designed to teach front-line employees basic Hoshin concepts
- Leader's guide with detail instructions and overheads
- Reproducible Participant manual
Excel Worksheet Template
- Visually tracks goals
- Produces pareto analysis and radar charts of goal progress
- Can easily be put on a Corporate intranet so goals are visible to managers and coworkers
Comprehensive Coordinator's guide
- Explains how to customize worksheets
- Explains how to collect the information needed to create the Hoshin process
Excel Goals and Action Matrix
Key Measure Target Action Summary (with Pareto Analysis)
Flexible Use Options:
- Purchase Hoshin Quick Start and rights to reproduce the Participant Manual
- $1500
- Scanlon Leadership Network Members may download the program at no cost from the member only area.
- Hire
the Scanlon Leadership Network to present the program at your location
and to work with you to install the Hoshin Process (Contact the Network
for a quote)
- Network Consultants can deliver the program at your site for $1750 per day plus travel expenses
- Network Consultants can help you customize the process to your location for $1750 plus travel expenses
Click here to obtain the Hoshin Quick Start™ brochure as a pdf file.
hoshin_quickstart_brochure 135.86 Kb
Call the Network Office at (517) 332-8927 or email
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to learn more or to order your Lean Sim. Machine or the Hoshin Quick Start Program.
Free Lean Materials
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