Podcast
Questions and Answers
What does the 'Check' phase in the PDCA cycle primarily focus on?
What does the 'Check' phase in the PDCA cycle primarily focus on?
- Metrics to evaluate both outcome and process. (correct)
- Training team members on problem-solving.
- Implementing pilot activities.
- Establishing new standards.
In lean culture, what does the term 'standardization' refer to?
In lean culture, what does the term 'standardization' refer to?
- A static set of rules that should never be altered.
- A process that prevents teamwork.
- The best current method subject to change. (correct)
- The elimination of all deviations.
What principle emphasizes being strict on problems while being supportive towards people in lean culture?
What principle emphasizes being strict on problems while being supportive towards people in lean culture?
- The Five Why's Principle
- The Check Principle
- The Warm Heart Principle (correct)
- The Standard Principle
What does the 'Act' phase in the PDCA cycle involve?
What does the 'Act' phase in the PDCA cycle involve?
Which of the following practices is commonly used to get to the root cause of problems in lean culture?
Which of the following practices is commonly used to get to the root cause of problems in lean culture?
What does the concept of Jidoka emphasize in lean management?
What does the concept of Jidoka emphasize in lean management?
Which statement reflects the philosophy of team members in a lean culture?
Which statement reflects the philosophy of team members in a lean culture?
What is the purpose of 'genchi genbutsu' in lean practice?
What is the purpose of 'genchi genbutsu' in lean practice?
How is teamwork depicted in a lean culture?
How is teamwork depicted in a lean culture?
What does 'muda' refer to in lean management?
What does 'muda' refer to in lean management?
What is emphasized by the 'do' concept in lean culture?
What is emphasized by the 'do' concept in lean culture?
Which principle is NOT associated with lean culture?
Which principle is NOT associated with lean culture?
What aspect of workplace culture does lean management prioritize?
What aspect of workplace culture does lean management prioritize?
Flashcards
Lean Culture
Lean Culture
A culture focused on continuous improvement, efficiency, and waste reduction through specific methods like PDCA, standardization, visual management, and teamwork.
PDCA Cycle
PDCA Cycle
Plan-Do-Check-Act; a four-step problem-solving methodology used to continuously improve processes, systems, and results.
Standardization
Standardization
Establishing the best current method for a process or task to eliminate inconsistencies and variability.
Visual Management
Visual Management
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Five Whys
Five Whys
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Visual Management Triangle
Visual Management Triangle
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Genchi Genbutsu
Genchi Genbutsu
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Jidoka
Jidoka
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Lean Culture (Intensity)
Lean Culture (Intensity)
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Lean Culture (Do)
Lean Culture (Do)
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PDCA Cycle
PDCA Cycle
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One-at-a-time production
One-at-a-time production
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Management as theatre
Management as theatre
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Study Notes
Lean Culture Objectives
- What is lean culture?
- PDCA
- Standardization
- Visual management
- Teamwork
- Paradox
- Intensity & do of lean culture
- How does lean culture feel?
What is Lean Culture?
- Daily experience of team members
- Current behavior
- Includes: Plan-do-check-act, Standardization, Visual management, Teamwork, Paradox, Intensity, the do concept
PDCA
- Grasping the situation (big picture, key parts, what is-should happen, trends, value-goal-related)
- Plan (5Ws + 1H, measurement plan, visual system)
- Do (contains its own PDCA cycle with pilot activities; assessment of team capabilities, assess current condition)
- Check (metrics to check outcome (final score) and process, go see what is happening)
- Act (reflect on condition, standardize when outcomes are on-target, make countermeasures when outcomes are substandard, stop bleeding or root cause)
- Manager's job: practice and teach PDCA daily
- Warm Heart Principle: Hard on problem, easy on people
Standardization
- Standard = best current method, continuously changing
- Standards make out-of-standard conditions obvious
- Problem = deviation from standard (gap)
- Problem-solving funnel
- Five Whys (get at root cause, usually inadequate standards, adherence to standard, or system)
Problem Solving
- Problem = deviation from standard (difference between what should be happening and what is happening)
- Problem solving process using a funnel
- Grasp the situation: actual vs standard, actual vs ideal
- Breakdown: Big vague concern
- 5Whys: identify point of why cause time and place events are causing abnormality
- Root cause: find the cause
- Countermeasures = solutions
Visual Management
- Visual management triangle
- Management as theatre (problems made visible)
- Line-side process reviews
- Safety/quality "auctions" (presentations, attendees can ask questions)
- Current condition presentations
- Hoshin (strategic) planning presentations
Teamwork
- Safety first (core value like productivity & quality)
- Uniforms (same regardless of position)
- No executive offices, no walls
- No executive dining rooms or parking
- Genchi genbutsu (Go see) - shop floor
Paradox
- Jidoka - Stop production so that production never has to stop.
- Standards - change all the time
- One-at-a-time production (more effective than batch)
- Maximizing unit efficiencies (does not always maximize overall efficiency)
- Don't make something unless customer orders it
- Team members (not industrial engineers develop standardized work)
- Seek perfection (even though we know we will never achieve it) (humility)
Intensity & "Do" of Lean Culture
- Intensity: more and greater demands (recognize muda (waste), kaizen (small improvements))
- Recognize strain
- Provide support & training
- Maintain intensity of improvement
- "Do" concept: path or way to follow
- Humility, Lifelong learning, Respect for people
How Does Lean Culture Feel?
- Disciplined
- Freewheeling
- Warm
- Indomitable (PDCA gives scientific discipline & freewheeling spirit, builds respect, creates warmth, no "them vs us")
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