132.1.4 - Lean Manufacturing

Getting Started with Lean

Having the Right Mindset

It is important when practicing Lean to have the "right" mindset. This includes things we have talked about previously:
- Continuous Improvement (KAIZEN)
- Focusing on the PROCESS, NOT PEOPLE
- Practicing "Good", People-Centric Lean Don't be a Bob!
But there are also other characteristics of a good Lean Mindset:
- Open-Mindedness - Everyone has good ideas, so don't let your own ideas drown out others'
- Mind Your Business - Focus on what is within your realm of control/responsibility - do not tell others how they could be more Lean, but instead focus on making yourself & your actions as Lean as possible
  - Oftentimes, doing this results in others taking notice of what you are doing and then wanting to learn/adopt your improvements/techniques

3S > 5S > 6S

5S/6S/3S is often the "starting point" for most companies when beginning to implement Lean, as it is something that can be fairly easily implemented company-wide with no additional resources, and it also brings near-instant, visibly-recognizable improvements
- However, just because it is the "starting point" doesn't mean it is something that should only be done initially and then forgotten. In truly Lean organizations, all members adapt 5S/6S/3S into their regular, ongoing activities
5S = developed by Toyota as a method for cleaning, organizing, & standardizing their workspaces
6S = Same as 5S, only with "Safety" added; typically seen in "Americanized" implementations of Lean
3S = Simplified Version of 5S, innovated by Paul Akers of FastCap:
- Here at CPTC we prescribe to the "3S" methodology, for several reasons:
  1. It is a more concise version of 5S/6S that focuses on actionable items/tasks
  2. It demonstrates the understanding that if the 3S's are done correctly, safety & sustainment are "built-in"

2 Second Lean

When applying 3S or any other Lean improvement in your life/work, one methodology that is easy to implement right away and has good bang-for-buck is 2 Second Lean
2 Second Lean is a method for continuous improvement in lean manufacturing. It is based on the idea that small, incremental improvements can have a big impact on overall efficiency and productivity.
- The principle behind 2 Second Lean is that employees should always be looking for ways to make their work processes more efficient, and that these improvements save just two seconds of process time.
  - A single 2-second improvement does not typically by itself make a significant difference, but many 2 second improvement add up to significant savings over time:
    - If each person made a 2 second process improvement, saving just 2 seconds per operation each day, after a year (365 days), that adds up to more than 12 minutes saved per day.
      - If the operation is performed multiple times per day - let's say 10 times - that results in saving a total of 2 hours (120 minutes) per day - that is 1/4 of an 8-hour shift, or 10 hours/week!
- This can include things like finding a more efficient way to organize tools or materials, streamlining a production process, or identifying and eliminating waste.
The importance of 2 Second Lean is that it promotes a culture of continuous improvement within the organization.
- By encouraging employees to constantly look for ways to improve their work, the organization can become more efficient and productive over time.
- This can lead to increased output, higher quality products, and reduced costs.
- Additionally, 2 Second Lean helps to engage and empower employees by giving them a sense of ownership and control over their work processes.
Overall, 2 Second Lean is an important aspect of lean manufacturing as it helps to create a more efficient and productive work environment that can lead to long-term success for the organization.

1.4✔ CHECKPOINT

3S-ing & 2-Second Lean at Home/School/Work

For one or more of the wastes you identified in the last checkpoint, use basic Lean tools & principles you have learned to:
- Create & apply 2-Second Improvements to the reduction of the waste(s)
- Apply 3S techniques to Sweep, Sort, & Standardize to the reduction of the waste(s)

Once done, add the following to the "Lean Wastes" Project page on your portfolio website, and upload documentation of your progress:
- Pictures(s)/Gif(s) and/or Summaries/Descriptions of:
  - The before & after of the 2 Second Lean improvement(s) you applied
  - The before & after of the 3S-ing you did

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