State of Minnesota, Department of Administration Enterprise Lean, Office of Continuous Improvement mn.gov/lean Lean Essentials

Lean is a time-tested method for improving performance and results by removing waste (non-value added activities) and standardizing work within a process. Lean embodies a way of thinking and acting to continually improve services.

7 Wastes (+1) Lean Principles 5 Whys

Waste to eliminate from the process • Customer focus: provide what customers want, Root cause identification tool when they want it, and how they want it 1 • Identify problem T • Transportation • Value: define value from the customer’s 2 • Ask, “What should happen?” I • Inventory perspective and relentlessly drive out waste 3 • Ask, “What did happen?” M • Motion • Respect: empower and engage employees to 4 • Ask, “Why?” 5 times W • Waiting improve products and services 5 • Complete action plan O • Overproduction • Results: set ambitious goals and measure results O • Overprocessing • Accountability and Transparency: follow through A3 D • Defects on commitments and communicate progress One-page problem solving or project S • Underutilized staff creativity • Continuous improvement: challenge the status quo, validate assumptions, Plan-Do-Check-Act, charter tool Poka-Yoke experiment and learn from experience Standard Work Mistake proofing WorkOut 5S How work should be done Kaizen Event Half-day method to help A simple method for creating 1 • Define process start and end teams identify work unit clean, safe, orderly, high 2 • Determine requirements A facilitated, rapid improvement event performing work issues and solutions 3 • Define process steps & time typically conducted over 3-5 days environments 4 • Create forms/documents 1 • Map current process 1S • Sort 1 • Define value streams 2 • Identify waste 2S • Set in order 5 • Set quality control checks 3 • Brainstorm improvements 2 • Identify challenges 3S • Shine 6 • Train supervisors and staff 4 • Map future process 3 • Brainstorm solutions 4S • Standardize 7 • Validate standard work 5 • Complete action plan 4 • Sort and prioritize 5S • Sustain 8 • Make adjustments State of Minnesota, Department of Administration Enterprise Office of Continuous Improvement [email protected] mn.gov/lean

Is idea Is key concern Does change Yes Is key concern Is current Yes Yes No No consistent a management have quick benefits, solving defects, errors condition Quick Win with Lean or personnel low risks, and low and mistakes? understood? principles? issue? costs?

Identified No No

Yes Yes Improvement Improvement Idea Idea Can team based Kaizen Yes Performance No Is a new product Problem Solving approach be applied Design Project Type management or service needed? within five days? Yes No

Complex Kaizen Event (DMAIC) Project Methodology and Tools

Plan Do Check Act Define Measure Analyze Improve Control • Project Charter • Swim Lane Map • Brainstorming • Brainstorming • Control Plan • Team Norms • Value Stream • Cause and Effect • Idea Box • Standard Work • SIPOC Diagram Map Analysis • Ranking and Voting • Post-Project Review • Voice of the • Spaghetti Map (Fishbone) • 2 x 2 Table • Storyboard Customer • Process Analysis • 5 Whys • Decision Matrix • Visual Measures Techniques • Control Chart • Affinity Diagram • Cost/Benefit Analysis • Stakeholder Map • Statistics • Relations • Impact Wheel • Benchmarking • Cost/Benefit Diagram • FMEA Analysis • Surveys • Mistake Proofing • Implementation Plan • Performance Measures • Before/After Analysis