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Baseline
Lean is about building and improving stable and predictable systems and processes to deliver to custom-
ers high-quality products/services on time by engaging everyone in the organization. Combined with
this, organizations need to create an environment of respect for people and continuous learning. It’s all
about people. People create the product or service, drive innovation, and create systems and processes,
and with leadership buy-in and accountability to ensure sustainment with this philosophy, employees
will be committed to the organization as they learn and grow personally and professionally.
Lean is a term that describes a way of thinking about and managing companies as an enterprise. Becom-
ing Lean requires the following: the continual pursuit to identify and eliminate waste; the establishment
of efficient flow of both information and process; and an unwavering top-level commitment. The con-
cept of continuous improvement applies to any process in any industry.
Based on the contents of The Lean Practitioners Field Book, the purpose of this series is to show, in
detail, how any process can be improved utilizing a combination of tasks and people tools and
introduces the BASICS Lean® concept. The books are designed for all levels of Lean practitioners and
introduces proven tools for analysis and implementation that go beyond the traditional point kaizen
event. Each book can be used as a stand-alone volume or used in combination with other titles based
on specific needs.
Each book is chock-full of case studies and stories from the authors’ own experiences in training
organizations that have started or are continuing their Lean journey of continuous improvement.
Contents include valuable lessons learned and each chapter concludes with questions pertaining to
the focus of the chapter. Numerous photographs enrich and illustrate specific tools used in Lean
methodology.
Baseline: Confronting Reality & Planning the Path for Success focuses on change management and
how to manage and accelerate change. The authors also outline how to get ready to implement lean,
how to baseline your processes prior to implementing Lean, and how to create a value stream map of
processes. This book also discusses Lean accounting.
and by Routledge
4 Park Square, Milton Park, Abingdon, Oxon, OX14 4RN
The right of Charles Protzman, Fred Whiton and Joyce Kerpchar to be identified as authors of this work has been asserted by
them in accordance with sections 77 and 78 of the Copyright, Designs and Patents Act 1988.
All rights reserved. No part of this book may be reprinted or reproduced or utilised in any form or by any electronic, mechanical,
or other means, now known or h ereafter invented, including photocopying and recording, or i n any information storage or
retrieval system, without permission in writing from the publishers.
Trademark notice: Product or corporate names may be trademarks or registered trademarks, and are used only for identification
and explanation without intent to infringe.
DOI: 10.4324/9781003185772
Typeset in Garamond
by KnowledgeWorks Global Ltd.
This book series is dedicated to all the Lean practitioners in the world and to two of the
earliest, my friend Kenneth Hopper and my grandfather Charles W. Protzman Sr. Kenneth
was a close friend of Charles Sr. and is coauthor with his brother William of a book that
describes Charles Sr. and his work for General MacArthur in the Occupation of Japan in some
detail: The Puritan Gift: Reclaiming the American Dream amidst Global Financial Chaos.
Acknowledgments................................................................................................................... xiii
About the Authors.....................................................................................................................xv
Original Authors......................................................................................................................xix
Introduction ............................................................................................................................xxi
vii
viii ◾ Contents
Chapter Questions............................................................................................................ 29
Notes................................................................................................................................ 29
Additional Readings..........................................................................................................31
Evils of Batching............................................................................................................... 77
Batching Is a Root Cause of the Eight Wastes and Drives Overproduction...................... 78
Batching Is a Hard Habit to Break............................................................................... 79
Batching Excuses.......................................................................................................... 79
Sometimes Batching Is a “Trust” Issue......................................................................... 80
One-Piece/Person Flow (OPF).......................................................................................... 80
Envelope Example.........................................................................................................81
Errors and Defects........................................................................................................ 82
One-Piece Flow Example............................................................................................. 82
One-Piece Flow and New Construction....................................................................... 83
Parallel Processing versus Batching.............................................................................. 84
Parallel Processing........................................................................................................ 84
Engineering Changes in a Batch System............................................................................85
Batching and Engineering Changes..............................................................................85
Hidden Gems............................................................................................................... 86
Why Do We Encourage Everyone to Check Out at the Same Time?........................... 86
Gray Area between Batch and Flow: Group Technology.............................................. 86
True Mixed Model Sequencing.................................................................................... 87
Homework: See for Yourself............................................................................................. 87
Chapter Questions............................................................................................................ 88
Notes................................................................................................................................ 88
Additional Readings......................................................................................................... 89
Chapter Questions...........................................................................................................141
Notes...............................................................................................................................142
Additional Readings........................................................................................................143
6 BASICS® Model.........................................................................................................145
BASELINE the Process...................................................................................................145
Baseline the Process/Metrics.......................................................................................145
Typical Baseline Continuous Improvement Metrics....................................................146
Data and What People Think......................................................................................146
Collection and Analysis: Current State............................................................................147
Determine Current State and Future State
Customer Demand......................................................................................................147
The Lost Customer Premium Story..................................................................................148
A Project Plan May be Necessary................................................................................149
Progression from Baseline to Benchmark.........................................................................149
Available Time............................................................................................................149
Takt Time Calculation................................................................................................152
Cycle Time..................................................................................................................153
Cycle Time and Takt Time: What’s the Difference?....................................................153
Three Types of Inventory.............................................................................................156
Raw Material...............................................................................................................156
Work in Process Inventory..........................................................................................156
Finished Goods Inventory...........................................................................................157
Measuring Inventory and Cash Flow...............................................................................157
Throughput Time: A Key Metric................................................................................158
Throughput Time and +QDIP....................................................................................158
Financial Metrics.............................................................................................................159
EVA............................................................................................................................160
EVA Calculation.........................................................................................................160
Return on Net Assets..................................................................................................161
What Is MVA?............................................................................................................161
MVA Calculation........................................................................................................161
Using EVA and MVA within a Company...................................................................162
Benefits of EVA Incentive Plan....................................................................................162
Sales per Employees.....................................................................................................163
Contribution Margin by Employee.............................................................................163
Peak Demand..............................................................................................................163
Little’s Law and Queuing Theory................................................................................164
Weighted Average Demand Calculations....................................................................165
What Is a Second Worth?............................................................................................167
Value Stream Mapping....................................................................................................168
The On-Time Delivery Metric Story...........................................................................168
Value Stream Discussion.............................................................................................171
Value Stream Mapping................................................................................................173
The Hoshin Plan and VSM Story................................................................................173
Parts of a Value Stream Map.......................................................................................174
Value Stream Map Icons.............................................................................................174
xii ◾ Contents
There are many individuals who have contributed to this book, both directly and indirectly, and
many others over the years, too many to list here, who have shared their knowledge and experi-
ences with us. We would like to thank all of those who have worked with us on Lean teams in
the past and the senior leadership whose support made them successful. This book would not
have been possible without your hard work, perseverance, and courage during our Lean journey
together. We hope you see this book as the culmination of our respect and appreciation. We apolo-
gize if we have overlooked anyone in the following acknowledgments. We would like to thank the
following for their contributions to coauthor or contribute to the chapters in this book:
◾◾ Special thanks to our Productivity Press editor, Kris Mednansky, who has been ter-
rific at guiding us through our writing project. Kris has been a great source of encour-
agement and kept us on track as we worked through what became an ever-expanding
six-year project.
◾◾ Special thanks to all our clients. Without you, this book would not have been possible.
◾◾ Russ Scaffede for his insight into the Toyota system and for his valuable contributions
through numerous e-mail correspondence and edits with various parts of the book.
◾◾ Joel Barker for his permission in referencing the paradigm material so important and inte-
gral to Lean implementations and change management.
◾◾ Many thanks to the “Hats” team (you know who you are).
◾◾ I would like to acknowledge Mark Jamrog of SMC Group. Mark was my first Sensei and
introduced me to this Kaikaku-style Lean System Implementation approach based on the
Ohno and Shingo teachings.
◾◾ Various chapter contributions by Joe and Ed Markiewicz of Ancon Gear.
For the complete list of acknowledgments, testimonials, dedication, etc. please see The Lean
Practitioner’s Field Book. The purpose of this series was to break down and enhance the original
Lean Practitioner’s Field Book into six books that are aligned with the BASICS® model.
Authors’ Note: Every attempt was made to source materials back to the original authors. In the
event we missed someone, please feel free to let us know so we may correct it in any future edition.
Many of the spreadsheets depicted were originally hand drawn by Mark Jamrog, SMC Group,
put into Excel by Dave O’Koren and Charlie Protzman, and since modified significantly. Most of
the base formatting for these spreadsheets can be found in the Shingo, Ohno, Monden, or other
industrial engineering handbooks.
xiii
About the Authors
xv
xvi ◾ About the Authors
executives had taken the course by 1956. The course continued until 1993. Many of the lessons
we t aught t he J apanese i n 1948 a re n ow b eing t aught t o A mericans a s “ Lean p rinciples.” The
Lean principles had their roots in the United States and date back to the early 1700s and later to
Taylor, Gilbreth, a nd Henry Ford. The principles were refined by Taiichi Ohno a nd e xpanded
by Dr. Shigeo Shingo. Modern-day champions were Norman Bodek (the Grandfather of Lean),
Jim Womack, and Dan Jones.
Charles participated in numerous benchmarking and site visits, including a two-week trip to
Japan in June 1996 and 2017. He is a master facilitator and trainer in TQM, total quality speed,
facilitation, career development, change management, benchmarking, leadership, systems think-
ing, high-performance work teams, team building, Myers-Briggs® Styles, Lean thinking, and sup-
ply chain management. He also participated in Baldrige Examiner and Six Sigma management
courses. He was an assistant program manager during “Desert Storm” for the Patriot missile-to-
missile fuse development and production program. Charles is a past member of SME, AME, IIE,
IEEE, APT, and the International Performance Alliance Group (IPAG), an international team of
expert Lean Practitioners (http://www.ipag-consulting.com).
We would like to acknowledge Chris Lewandowski, Steve Stenberg, and Patrick Grounds as
original authors of The Lean Practitioner’s Field Book.
xix
Introduction
This book is the first of the six books BASICS Lean® Implementation Series and was adapted
from The Lean Practitioner’s Field Book1: Proven, Practical, Profitable, and Powerful Techniques
for Making Lean Really Work. In Book 1, we discuss the Lean philosophy and provide a Lean
Overview where we explore batching, the BASICS Lean® Business Delivery System, how to con-
duct Lean assessments, and preparing for a Lean Implementation (Kaikaku). We then begin with
the B in the BASICS Lean® Implementation Model, which is BASELINE.
The books in this BASICS Lean® Implementation Series take the reader on a journey begin-
ning with an overview of Lean principles, culminating with employees developing professionally
through the BASICS Lean® Leadership Development Path. Each book has something for everyone
from the novice to the seasoned Lean practitioner. A refresher for some at times, it provides soul-
searching and thought-provoking questions with examples that will stimulate learning opportuni-
ties. Many of us take advantage of these learning opportunities daily. We, the authors, as Lean
practitioners, are students still thirsting for knowledge and experiences to assist organizations in
their transformations.
This series is designed to be a guide and resource to help you with the ongoing struggle to
improve manufacturing, government, and service industries throughout the world. This series
embodies true stories, results, and lessons, which we and others have learned during our Lean
journeys. The concept of continuous improvement applies to any process in any industry.
The purpose of this series is to show, in detail, how any process can be improved by utilizing a
combination of tasks and people tools. We will introduce proven tools for analysis and implemen-
tation that go far beyond the traditional point kaizen event training. Several CEOs have shared
with us; had they not implemented Lean, they would not have survived the Recession in 2008 and
subsequent downturns.
Many companies prefer we not use their names in this book as they consider Lean a strategic
competitive advantage in their industry, and some of these companies have now moved into a lead-
ership position in their respective markets; thus, we may refer to them as Company X throughout
the series. We explain to companies that Lean is a five-year commitment that never ends. Eighty
to ninety percent of the companies with whom we have worked have sustained their Lean journeys
based on implementing our BASICS® Lean approach that we will share with you in this book.
The BASICS Lean® Implementation Series discusses the principles and tools in detail as well as
the components of the House of Lean. It is a “how to” book that presents an integrated, structured
approach identified by the acronym BASICS®, which when combined with an effective business
strategy can help ensure the successful transformation of an organization. The Lean concepts
described in each book are supported by a plethora of examples drawn from the personal experi-
ences of its many well-known and respected contributors, which range from very small machine
shops to Fortune 50 companies.
xxi
xxii ◾ Introduction
The BASICS Lean® Implementation Series has both practical applications as well as applica-
tions in academia. It can be used for motivating students to learn many of the Lean concepts and
at the end of each chapter there are thought-provoking questions for the reader to help digest the
material. The investment in people in terms of training, engagement, empowerment, and personal
and professional growth is the key to sustaining Lean and an organization’s success. For more on
this topic, please see our book Lean Leadership BASICS®. Lean practitioners follow a natural flow,
building continually on previous information and experiences. There is a bit of the Lean practitio-
ner in all of us. Hopefully, as you read these books to pursue additional knowledge, as a refresher
or for reference, or for academia, it can help expand your knowledge, skills, and abilities on your
never-ending Lean journey.
Note
1. The Lean Practitioner’s Field Book 1st Edition by Charles Protzman (Author), Fred Whiton (Author),
Joyce Kerpchar (Author), Christopher Lewandowski (Author), Steve Stenberg (Author), Patrick
Grounds (Author), Productivity Press; 1st edition (April 4, 2016).
Chapter 1
Lean Philosophy
and Foundations
No one has more trouble than the person who claims to have no trouble.
Taiichi Ohno
Father of the Toyota Production System (TPS)
Brief History
There are literally hundreds of books that address Lean thinking and the Lean production system.
However, very few explain how to implement the tools we will share with you. Lean is a term that
describes a way of thinking about and managing companies as an enterprise. Becoming Lean
requires the following:
The term Lean was coined by John Krafcik in his paper “Triumph of the Lean Production
System” for his master’s thesis at Massachusetts Institute of Technology (MIT) Sloan School of
Management in 1988.1 It was introduced by James Womack and Dan Jones in their book titled
Lean Thinking2 after a five-year MIT study of the automotive industry described in a book titled
The Machine That Changed the World.3 In the book and on the Lean Enterprise Institute (LEI)
website,4 Lean is described as the five-step process for guiding the implementation of Lean tech-
niques as easy to remember, but not always easy to achieve:
1. Specify value from the standpoint of the end customer by product family.
2. Identify all the steps in the value stream for each product family, eliminating whenever pos-
sible those steps that do not create value.
DOI: 10.4324/9781003185772-1 1
2 ◾ Baseline
3. Make the value-creating steps occur in tight sequence to ensure the product flows smoothly
toward the customer.
4. As flow is introduced, let customers pull value from the next upstream activity.
5. As value is specified, value streams are identified, wasted steps are removed, and flow and
pull are introduced. Begin the process again and continue it until a state of perfection is
reached in which a perfect value is created with no waste.
Lean has its roots in the United States. Such notables as Frank and Lillian Gilbreth, Frederick
Taylor, and Henry Ford all practiced principles that make up Lean today. The 1970s oil crisis
and then New United Motor Manufacturing, Inc. (NUMMI), the California-based joint venture
between General Manager and Toyota, put Lean on the map. The Toyota Production System
(TPS) has become synonymous with Lean; however, Lean is not just for automotive companies.
This system will work for any company, healthcare organization, service industry, or government/
military entity. Since many of our processes are unique and every company’s culture is distinctive,
one must adapt the principles and tools to the environment in which one implements. This meth-
odology has produced significant results for many companies.
Lean will sustain, but only if implemented properly and with ongoing training and people
development. Lean must be rolled out enterprise-wide (not just shop floor) requiring an overall
transformational change within the company. It must be championed and driven from the top of
the organization. It must include all functional areas (i.e., finance, sales, marketing, HR, informa-
tion systems [IS], operations), at all levels, from the board of directors to the person on the front
line on the shop floor or in the office. It must include all value streams from the supply chain to
the customers to recycling within the overall enterprise system framework.
Lean will not be successful if it is directed only at the frontline staff, promoted by someone
within middle management, or if it is measured by the number of point kaizen events conducted
each year. Today we find most companies have pockets of excellence5 or what we call Lean lite and
have struggled to sustain or had to relaunch Lean multiple times. Some feel they have completed
their Lean implementations or have improved enough.
Implementing Lean requires a counterintuitive paradigm shift in thinking to offset the ever-
prevalent resistance to batching inherent in the current system. This includes the need to adopt new
accounting techniques and potentially instituting significant structural organizational changes. In
short, developing a new way of thinking.
A consistent theme throughout this series (see Figure 1.1) is the balance and integration
required between philosophy and tools. Learning to implement the task portion of is often not
difficult; however, the people and philosophy piece which is emergent and always the most chal-
lenging. We cannot overstate the importance of separating these two pieces and implementing
and integrating them together to achieve a complete Lean implementation. All the chapters in
this series have been reviewed or written by leading experts in their fields and practicing internal
company and external consulting Lean practitioners.
result of changes you or someone prior to you made in the past and these are the most difficult to
change. Listed below are stories and anecdotes associated with our Lean journey.
When we cleaned out the inspection area, each station was full of various lots of materials
the inspectors were working on. Instead of finishing one lot, they would take each lot and run
it through one of the inspection operations, then run all the lots through the second operation,
etc., until they were all completed. As a result, all the delinquent lots would sit until the last
operation was completed for the lot. A significant amount of time was lost moving boxes of
parts around the inspection area due to lack of space. It was difficult to find where a particu-
lar lot was located as there was so much material in inspection. Every day, this led to greater
amounts of expediting and searching by supervisors and managers trying to track down and
expedite this material. The management staff turned into day-to-day firefighters and high-paid
expediters
Suddenly, something amazing started to happen. Over a two-week period, we cut our backlog
from an average of 16 weeks to 6 weeks! In addition, we found there was plenty of space in the
inspection department once we removed the excess inventory. During this effort, since parts were
assumed to be lost by the planning department, we realized that we had double or even triple
ordered much of the same material waiting for inspection. No one bothered to get up from their
comfortable office chairs to look for the material, and if they did, there was so much material; it
was just easier to order more than to look for it in the disorganized holding area.
Within four weeks, we were down to a two-week backlog and within six weeks, we caught up.
Once we caught up, everyone tried to go back to the old way of doing it; however, we wouldn’t let
them. We freed up a tremendous amount of space not only in inspection but also in the holding
area as well. Everything now smoothly flowed through the dock-to-stock process. This is when we
first learned the true power of one-piece flow (now called Lean); however, we still didn’t under-
stand the breadth or true vision of it at the time.
When we went back to analyze the root cause of the problem, we discovered the reason we
were so far behind was because we were batching the items through inspection. Batching, in this
case, meant the inspectors would go into the receiving holding area filled and take four or five lots
Lean Philosophy and Foundations ◾ 5
of material. Since they could pick and choose which boxes to work on, they would naturally look
for the easiest things to work on first and leave the harder items for someone else.
Lesson learned: Batching environments are fraught with waste, lack of space, and delays. Batch
environments always create the perception of the need for more space. In a batch environment,
people usually take the easiest piece to work on first instead of using FIFO, the first in first out or
EDD earliest due date principle. We also find it easier to reorder something instead of having to
conduct an endless search for it. You cannot always depend on what others tell you. You must get
up out of your chair and “go see” for yourself to identify the problems.
Once you “Lean out” an area, the supervision of the area becomes much easier, thus creating
time to work on small improvements. Space which seems initially to be at a premium turns out
to be “excess” space. Results can be obtained quickly within a specific area or process. Root cause
analysis and management-by-fact may initially solve the problem, but you cannot switch back to
the old ways of doing things if one wants to avoid reoccurrence of the problem.
Carousels9
As part of my new position in the dock-to-stock process, I inherited a capital request from the prior
director to install two brand-new carousels (like the system shown in Figure 1.3) on the second
floor of our stockroom to replace all the shelves of material. We already had two robotic retrieval
systems on the first floor with which we always had problems. For example, if the power went out,
we couldn’t pick parts and would shut down assembly. We always had to have someone trained
and available to operate them. Parts would get lost and servicing them was expensive. It was going
to be several hundred thousands of dollars (not including installation and ongoing maintenance)
and justified with a rather large return on investment (ROI) analysis. I was told to finish up inter-
viewing the various suppliers and provide a recommendation. It occurred to me after some Lean
training that we were going to spend all this money to manage a bunch of inventory that was now
considered evil. So, my recommendation was to cancel the capital appropriation request.
My eventual goal became to eliminate the need for my job, and within three years of my
assignment which I achieved. We had successfully vacated the separate two-story stockroom
building and moved the material to the production floor at the point of use where it belonged.
Not only did we save hundreds of thousands of capital expenditure dollars, but we also eliminated
picking, counting, and kitting parts to the floor. When we cleaned out the old robotic system in
the stockroom, we found hundreds of previously lost parts that were misallocated and reordered.
Lesson Learned: Installing carousels and automated material storage equipment makes it
much harder to implement Lean. Once it is purchased, accounting wants it used so they can
depreciate it. The goal should be to eliminate stockrooms along with all the waste they create. The
next time you look at an automated material storage device, make sure it is not just adding cost to
store material you don’t want in storage. We also learned and embraced the idea of removing waste
by always working to eliminate our own jobs.
Slide Line10
The next experience with Lean involved the use of slide lines. Our division manufactured electronic
circuit boards and systems equipment primarily for the military. We invested significant capital
in machines that sequenced transistors and diodes (Figure 1.4), so they could be put onto another
says Horace of the writers of his day. In our day the saying applies in
most force to that class of poemata, which pretends to narrate the
epic of life in the form of prose. For the docti as well as the indocti—
men the most learned in all but the art of novel-writing—write
novels, no less than the most ignorant; and often with no better
success. One gentleman wishing to treat us with a sermon, puts it
into a novel; another gentleman, whose taste is for political
disquisition, puts it into a novel; High Church and Low Church and
no Church at all, Tories and Radicals, and speculators on Utopia,
fancy that they condescend to adapt truth to the ordinary
understanding, when they thrust into a novel that with which a novel
has no more to do than it has with astronomy. Certainly it is in the
power of any one to write a book in three volumes, divide it into
chapters, and call it a novel; but those processes no more make the
work a novel, than they make it a History of China. We thus see
many clever books by very clever writers, which, regarded as novels,
are detestable. They are written without the slightest study of the art
of narrative, and without the slightest natural gift to divine it. Those
critics who, in modern times, have the most thoughtfully analysed
the laws of æsthetic beauty, concur in maintaining that the real
truthfulness of all works of imagination—sculpture, painting, written
fiction—is so purely in the imagination, that the artist never seeks to
represent the positive truth, but the idealised image of a truth. As
Hegel well observes, “that which exists in nature is a something
purely individual and particular. Art, on the contrary, is essentially
destined to manifest the general.” A fiction, therefore, which is
designed to inculcate an object wholly alien to the imagination, sins
against the first law of art; and if a writer of fiction narrow his scope
to particulars so positive as polemical controversy in matters
ecclesiastical, political, or moral, his work may or not be an able
treatise, but it must be a very poor novel.
Religion and politics are not, indeed, banished from works of
imagination; but to be artistically treated, they must be of the most
general and the least sectarian description. In the record of the Fall
of Man, for instance, Milton takes the most general belief in which all
Christian nations concur,—nay, in which nations not Christian still
acknowledge a myth of reverential interest. Or again, to descend
from the highest rank of poetry to a third rank in novel-writing;
when Mr Ward, in his charming story of ‘Tremaine,’ makes his very
plot consist in the conversion of an infidel to a belief in the
immortality of the soul, he does not depart from the artistic principle
of dealing, not with particulars, but with generals. Had he exceeded
the point at which he very wisely and skilfully stops, and pushed his
argument beyond the doctrine on which all theologians concur, into
questions on which they dispute, he would have lost sight of art
altogether. So in politics—the general propositions from which
politics start—the value of liberty, order, civilisation, &c.—are not
only within the competent range of imaginative fiction, but form
some of its loftiest subjects; but descend lower into the practical
questions that divide the passions of a day, and you only waste all the
complicated machinery of fiction, to do what you could do much
better in a party pamphlet. For, in fact, as the same fine critic, whom
I have previously quoted, says, with admirable eloquence:—
“Man, enclosed on all sides in the limits of the finite, and aspiring to get beyond
them, turns his looks towards a superior sphere, more pure and more true, where
all the oppositions and contradictions of the finite disappear—where his
intellectual liberty, spreading its wings, without obstacles and without limits,
attains to its supreme end. This region is that of art, and its reality is the ideal. The
necessity of the beau-ideal in art is derived from the imperfections of the real. The
mission of art is to represent, under sensible forms, the free development of life,
and especially of mind.”
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