Hi, this is Mike Negami, Lean Sigma Black Belt.
Today, I’ll demonstrate the first steps of the Analyze Phase, the Non-Value-Added
Analysis and the 7-Waste Analysis.
In Lean Sigma we’ve added one more to the 7 Wastes, so we call it the 8-Waste Analysis.
By these analyses, you can sort out many issues of your target process.
You can conduct both the analyses on the Value Stream Map that you would usually have made
in the Define Phase.
An earlier video explains how to make a Value Steam Map.
Please click the link there and watch the video.
This is my case-study project’s current process flow.
See this Value Stream Map template.
Click the link, Here is a link titled “Non-Value-Added Analysis and the 8-Waste Analysis”.
then the both analyses’ guidelines will appear.
Let’s follow the guidelines and make the analyses.
The first one is the Non-Value-Added Analysis.
Gather the target process’s supervisors and ask them these two questions for each
process step: “Do customers want to pay for this operation?”
and “Does this operation produce something that customers want?”
The purpose is to find non-value-added operations that are not beneficial for your customers
in your process.
Next is the 8-Waste Analysis.
In Lean Sigma, we remember the 8 Wastes as DOWNTIME.
I explained about this in another video.
Please click the link there and watch the video.
Here are the 8 Wastes: Defects, Overproduction, Waiting, Non-value adding processing, Transportation,
Inventory, Motion, and the 8th waste, Employees Unused Creativity.
These are all non-value-added operations.
Find all operations that apply in your Value Stream Map.
Let’s say, we have many delivery mistakes.
Click this link, “Kaizen Point Icon”.
Type the Kaizen point and drag it around to the delivery flow.
If you would like the Kaizen Point Icon to be more transparent, select only the shape
by clicking it twice, then right-click it and select ‘Format Shape…’.
You’ll see ‘Transparency’, so make it 50%.
Also change its font color to red.
Another example: delivery drivers are frequently waiting a long time for invoices to be prepared.
Copy the Kaizen Point Icon and change the text.
It’s quicker this way.
In service operations, the 8th waste, Employees Unused Creativity is especially important.
Front line people often have solutions already.
Not only employees, are there any things or information that you haven’t used that have
been wasted?
Record those wastes here.
For instance here, we found that drivers got product return reasons from customers, but
the information was not utilized at all.
Overall, we have many Kaizen Points here.
Ideally speaking, we would like to design a new process that solves all these Kaizen
Points, but that may derail your project with scope creep.
Look back at your Project Charter and see the project’s purpose and goal, then you
can see what’s most important in your project and identify your Vital-Few Kaizen Point.
In our case-study project, our conclusion is “To utilize product return reasons daily
is essential.”
We practiced the ‘Non-Value-Added Analysis and 8-Waste Analysis.
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Thanks.