Production Operations Transition-To-Lean Roadmap
Supply Chain/External Environment
• Legal
• Environmental
• Government Reqd. Systems
(MMAS, EVMS, etc.)
Enterprise / Production System Interface
• Financial
• Information
• Procurement
• Engineering
• Quality
• Safety
• Training and Human Resources
• Workforce/Management Partnership
Phase 0
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Phase 6
Adopt Lean
Paradigm
Prepare
Define
Value
Identify
Value Stream
Design
Production System
Implement Flow
Implement Total
System Pull
•Build vision
•Build vision
•Establish need
•Establish need
•Foster lean
•Foster lean
learning
learning
•Make the
•Make the
commitment
commitment
•Obtain Sr.
•Obtain Sr.
Mgmt. buy-in
Mgmt. buy-in
•Integrate with
•Integrate with
Enterprise
Enterprise
Level
Top
Level
•Establish an
Leadership
•Establish an
Operations
Operations
Lean
Lean
Commitment Implementation
Implementation
Team(s)
Team(s)
•Develop
•Develop
implementation
implementation
strategy
strategy
•Develop a plan
•Develop a plan
to address
to address
workforce
workforce
changes
changes
•Address Site
•Address Site
Specific
Specific
Cultural Issues
Cultural Issues
•Train key
•Train key
people
people
•Establish target
•Establish target
objectives
objectives
(metrics)
(metrics)
Lean
Roadmap
•Select initial
•Select initial
implementation
implementation
scope
scope
•Define
•Define
customer
customer
•Define value •Define value Quality,
Quality,
Schedule, and
Schedule, and
Target Cost
Target Cost
•Record current
•Record current
state value
state value
stream
stream
•Chart product
•Chart product
and
and
information
information
flow
flow
•Chart operator
•Chart operator
movement
movement
•Chart tool
•Chart tool
movement
movement
•Collect
•Collect
baseline data
baseline data
+
•Develop a future
•Develop a future
state value
state value
stream map
stream map
•Identify takt time
•Identify takt time
requirements
requirements
•Review
•Review
make/buy
make/buy
decisions
decisions
•Plan new layout
•Plan new layout
•Integrate
•Integrate
suppliers
suppliers
•Design visual
•Design visual
control system
control system
•Estimate and
•Estimate and
justify costs
justify costs
•Plan TPM
•Plan TPM
system
system
+
•Standardize
•Standardize
operations
operations
•Mistake proof
•Mistake proof
processes
processes
•Achieve process
•Achieve process
control
control
•Implement TPM
•Implement TPM
•Implement self•Implement selfinspection
inspection
•Eliminate/
•Eliminate/
reduce waste
reduce waste
•Cross train
•Cross train
workforce
workforce
•Reduce set-up
•Reduce set-up
times
times
•Implement cell
•Implement cell
layout
layout
•Implement visual
•Implement visual
controls
controls
+
+
Phase 7
•Select
•Select
appropriate
appropriate
production
production
system control
system control
mechanism
mechanism
•Strive for single
•Strive for single
item flow
item flow
•Level and
•Level and
balance
balance
production flow
production flow
•Link with
•Link with
suppliers
suppliers
•Draw down
•Draw down
inventories
inventories
•Reassign
•Reassign
people
people
•Re-deploy/
•Re-deploy/
dispose assets
dispose assets
+
Strive for Perfection
•Team development
•Optimize quality
Expand
Internally/Externally
•Institutionalize 5S
•Institute Kaizen events
•Remove system barriers
• Expand TPM
• Evaluate against
target metrics
• Evaluate progress
using lean maturity
matrices
ENTRY
© 2000 Massachusetts Institute of Technology
IMPROVED
COMPETITIVE
POSITION
6/5/00