12Feb 2021 by Steve Musica No Comments
Continuous Flow

Continuous Flow

Lesson
Every Lean expert will tell you that continuous flow of value is the goal of a Lean process. Batching work is the opposite of continuous flow, yet most people batch jobs because they feel it is more efficient. For example, if we are baking a cake we may as well bake a second cake while the recipe book is open, all the ingredients are out, and the oven is on. The time for baking two cakes in a batch will be only slightly more than baking a single cake. The average time per cake is, therefore, lower when batching - this is more efficient! So if batching is more efficient, are the Lean experts wrong?   Why we batch work All people, even lean practitioners, batch some of their work.…
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28Apr 2020 by Steve Musica No Comments
The Business Case for Lean

The Business Case for Lean

Lesson
Five Lean East case studies that show the benefits of Lean Thinking The Lean East team is focused on teaching and applying proven Lean Six Sigma principles and tools to develop high performing organizations. We focus specifically on organizations that provide customers with a service (i.e. healthcare, government, financial, insurance, education, construction, repairs, etc.) rather than a product. Lean Six Sigma has a long track record of success in manufacturing, but only recently became embraced by service-based industries. Some of our clients use Lean thinking as a strategic differentiator – far surpassing their previous results (and their competition). Some of our clients select us because of our expertise in Lean Six Sigma methodology. Other clients have “no idea what this Lean stuff is about.” Our goal in this post is…
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23Feb 2020 by Steve Musica 3 Comments
The Difference Between Push and Pull

The Difference Between Push and Pull

Lesson
  This post focuses on the difference between push and pull in Lean. The goal of Lean is for every process to “flow value at the pull of the customer.” The key terms in this statement are defined below: [caption id="attachment_3048" align="alignright" width="150"] This symbol represents "pull" in Lean value stream mapping[/caption] The ultimate Customer is the end-user – who the product or service is providing value for. The other customer is the next step in the process. What does the next step need, and when do they need it? Flow refers to how value is created in a process. In a “perfect process,” value is created during every step, without any waste (or delay) in the process. Value is defined by the customer (end-user or next step). Every step…
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25Dec 2019 by Steve Musica No Comments
Develop Scientific Thinking with Lean Kata

Develop Scientific Thinking with Lean Kata

Lesson
This month we are happy to share a simple yet powerful tool that will benefit any organization. It is the Lean Kata approach for developing a culture of scientific thinking at all levels of any organization.     What does the word “kata” mean? Kata is the Japanese word for “form” and refers to a detailed, choreographed pattern of movements practiced alone or in groups. Anyone who has ever practiced the martial arts has performed katas in front of a sensei to advance and earn additional belts. The kata allows the trainee to memorize and perfect the movements being executed so they can easily make the movements later using muscle memory. The Lean Kata was developed by Toyota and has been well described in the Mike Rother book, Toyota Kata:…
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16Sep 2019 by Steve Musica No Comments
The Checklist Manifesto

The Checklist Manifesto

Summary
  This post summarizes a wonderful book that is celebrating its ten-year anniversary. Atul Gawande wrote the best-seller The Checklist Manifesto: How to Get Things Right in 2009. It was the third book by the author and has become influential in healthcare and beyond. Gawande is a general surgeon at the Brigham and Women's Hospital in Boston, a staff writer for The New Yorker, and an assistant professor at Harvard Medical School and the Harvard School of Public Health. In June of 2018 he was named CEO of the recently formed healthcare venture Haven, owned by Amazon, Berkshire Hathaway, and JP Morgan Chase.   I’ll let Gawande summarize the core idea from his book: “Avoidable failures are common and persistent, not to mention demoralizing and frustrating, across many fields –…
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19Aug 2019 by Steve Musica 1 Comment
Allowing For Trial & Error

Allowing For Trial & Error

Lesson
  Lean East shares our improvement cycle and the need to experiment to learn and grow. We are pleased to offer this monthly lesson as a video post! You can read the lesson below, which is a formatted transcript of the presentation, or watch the 5-minute video embedded at the end.   Allowing For Trial & Error: A Better Way To Grow & Compete Have you ever worked in a place where the goal is to be unnoticed and the boss visits your area only if you are about to hear bad news? I have seen too many organizations where employees just go through the motions, doing what they are told. Raises and advancements at these workplaces are based primarily on not making mistakes. Employees are told what to do…
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10Apr 2019 by Steve Musica 1 Comment
Are you a “Super Nurse” on your Team?

Are you a “Super Nurse” on your Team?

Lesson
  Does your organization have a person on staff who everyone can go to in order to get a problem solved? For example, someone who knows how to obtain guest Wi-Fi access for a visiting contractor? Who is the same person who can always find that hidden file on the network, and knows how to correct the mistake in your EMR or MRP system? Perhaps your organization is a customer-facing business and this person also goes above and beyond to follow up with a customer who has a special request and double-checks every item before your product goes out the door. Picture a person on your team who matches this description. Or, are you that person on your team? People who save the day and rescue a team from disaster…
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30Jan 2019 by Steve Musica 1 Comment
8 Lean Wastes: Transportation vs Motion

8 Lean Wastes: Transportation vs Motion

Lesson
  Learn about the 8 Lean wastes to minimize from your processes and how to differentiate between the wastes of Motion and Transportation.   We enjoy teaching the 8 Wastes of Lean Thinking to our clients and the participants in our training workshops. As instructors, we share examples of wastes from our professional experience in both manufacturing and service-related organizations. Together, we brainstorm ways in which the wastes reveal themselves in our attendees' organizations. One question that gives us pause in every Introduction to Lean Thinking workshop is the request to explain the nuance of two 'movement' wastes - motion and transportation.     Motion The motion waste focuses on the movement of people or equipment that is unnecessary. It is any movement beyond the minimum required for completing the process step.  The motion…
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14Sep 2018 by Steve Musica No Comments
Developing High-Performing Organizations

Developing High-Performing Organizations

Summary
Lean East was founded in 2010 with a mission to bring out the best in organizations by bringing out the best in people. We focus on introducing proven Lean Six Sigma improvement methods to service organizations in Maine and New England – in industries including healthcare, government, insurance, construction, and finance. Many of the clients we have partnered with have had a common goal – to improve their culture and performance and provide better customer service. Some client organizations want to improve their processes and provide more customer value with less waste. Others focus more on changing work culture, training their leaders and staff, and improving teamwork. One client wanted to improve in multiple dimensions and move the company from good to great. A common theme with all our clients is…
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20Aug 2018 by Steve Musica No Comments
The Toyota Way

The Toyota Way

Lesson
  Lean principles are based largely on studies of the Toyota Production System (TPS) from the early 1980s and influence manufacturing and service organizations across the world today. In 2001 the Toyota Motor Corporation summed up their philosophy, principles, and values in an internal document they referred to as, “the Toyota Way 2001.” The document expanded upon TPS with additional leadership and management practices that have made Toyota one of the most respected companies in the world.  Author Jeff Liker visited Toyota and summarized these principles in his 2004 book, The Toyota Way: 14 Management Principles from the World’s Greatest Manufacturer. The book covers Toyota’s history, successes, and ideas with many great Toyota case studies; this post will focus on summarizing Toyota's 14 Principles. How many of these principles are followed…
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