What is the difference between a “Process” and a “Lean Process”?
I like to imagine a black box where:
Something come in and something different come out!
A “Process” is is a process that transforms something that comes in.
A “Lean Process” is a process that transforms something that comes in
with the less waste as possible.
Do you agree?
In this page, I want to explain you how to create a Lean Process.
Difference Between Process and “Lean Process”
From the “Cambridge Dictionary”,
Process = a series of actions that you take to achieve a result.
I like this definition.
if I give a paper to be stamped or signed.
In = Paper to be stamped
Process = Stamping
Out = Paper Stamped
Are we on the same page?
I hope yes!
what is missing in the definition I gave before?
there is no reference on “how long it takes the process”.
In other words,
what if the process of stamping is long 2 days?
How do you feel if for this simple process you have to wait 2 days?
Honestly, I do not think you will be happy with this!
a lean process takes into account the time that needs the process to be completed.
time is fundamental once the quality is granted 100%.
The importance of the scale.
Firstly, what we are discussing in this page is a single process.
Then, it is important to underline that a Lean Enterprise is made by a lot of Lean Processes that has to be implemented in a long journey
Cannot be overnight!
My suggestion is to select the processes to be improved by the Value Stream Map and then, process by process, improve the single points, then the flow, then the company.
An example of a Stamping Process
come back to the “stamping process” and imagine that it take 2 Days and that our customer is not happy with this time.
As a result of this situation, we have to transform this “Process” in a “Lean Process” by removing the wastes and focusing our action on time.
the goal of the time has to be achieved with 100% of the quality!
I know what are you thinking …
If you want more quality you have to spend more money and more time.
Yours is an old way of thinking.
Look at what Deming used to tell.
You have to believe that there is a method to have more quality with less time.
You have only to create a Lean Organization that use Lean Management.
In the final analysis,
the difference between a Process and a Lean Process is that in the Lean Process we focus on the quality and time and the organization struggle every day to find a better way to lead the process.
How to Transform the Stamping Process in a Lean Stamping Process.
Firstly, as already mentioned, you have to change your mindset and understand deeply what is lean.
#Step 1 – Observe the process with a particular focus on the seven wastes.
You have to observe and analyze the “stamping process” trying to see the seven wastes.
Here there is a video that will help you to remember the seven wastes forever.
# Step 2 – Involve People with a focus on Quality and Time.
with the method of the 5 Steps to Lean Management involve people and struggle everyday to remove the wastes you found during the observation.
We treated in another page that the people are one of the most powerful Lean Tools.
# Step 3 – Give a Metric and track it
create a metric that could be tracked to give people the contribution of their work on the improvement.
In this hypothetical example, the people involved discovered that:
- 5S was missing
- The material to stamp often was unavailable
- The office was overburden with papers that has not to be processed there
- The “Spaghetti Chart” was very long and intricated
All these points lead to wastes that lead to a process time of 2 days!
# Step 4 – Try and Implement the Solutions Proposed.
After some days,
the Leadership and the people involved decided to try and implement what arose during the daily meeting set and the process time after implementation dropped to 2 minutes!
I know that you do not believe it!
This is the first step,
You have to believe it!
If you believe it, and follow the steps, you will achieve!
It is proven!
Every industry performs several processes.
Any of these processes can be transformed in a “Lean Process” by following these steps.
1 – Firstly, observe the process with a particular focus on the seven wastes.
2 – Secondly, Involve People with a focus on Quality and Time.
3 – Thirdly, Give a Metric and track it.
4 – Finally, Try and Implement the Solutions Proposed.
I will be very grateful if you can comment what is a “Lean Process” for you!