It’s very exciting to see the increasing coverage Lean Manufacturing (or just Lean) is getting. From my experience, Lean provides very useful and intuitive methodologies for process improvement and streamlining as well as a more robust set of tools for advanced implementations. A good number of books have been written about Lean Manufacturing over the years, from its origins in the automotive industry with Toyota (hence the alias TPS for Toyota Production System) through other implementation to the influential ‘The Lean Startup‘
In its most basic form, Lean provides guidelines and ideas for reducing or eliminating waste in process driven operations. Waste, for this purpose, is defined as anything that does not add value that the customer will appreciate and pay or. There are seven different types of waste (sometimes known by their Japanese name ‘Muda‘) that are recognized: Transportation, Inventory, Motion, Waiting, Over Processing, Over Production and Defects. Additionally, for some organizations, including Enterprise Support, I believe it is useful to add Unused Employee Talent as the eighth waste
When discussing these wastes we should keep in mind that some apply to the work in progress (from cases and knowledge items through equipment being repaired to employment candidates) while others apply to the resources (people or machines) that perform the work. We should also know that Lean distinguishes between necessary waste and unnecessary waste. Necessary waste, known as ‘Type I’, could, for example, be any activity that’s required for compliance – from inventory audit to health and safety drills. Un-required waste is known as ‘Type II’, and should be eliminated. While the first distinction is built into each waste’s definition, determining which wasteful activity is necessary and which isn’t is subject to individual analysis
With this understanding, let’s look at each waste and how it can manifest itself in the enterprise support world. With that understanding we can determine how reducing or eliminating it can help us improve our operation. We should also note that certain wastes can generate other types of waste:
- Transportation – is focused on the work items, and can equally apply to physical movement as well as to transitions of ownership or responsibility. For example, are we moving cases unnecessarily between teams and individuals? How much extra work is created every time we change case ownership? For hardware support organizations, are we moving returned equipment between departments or locations unnecessarily? Excessive transportation can sometimes lead to increased inventory – another waste
- Inventory – this is another work item waste. Are we keeping cases open unnecessarily? Why do we have so many open cases? In what stages are they open? Do we respond to all recruitment candidates as soon as a decision was made? How much equipment do we have waiting to be repaired? What’s keeping us from getting that equipment to the lab? How much inventory do we keep to support potential customer failures?
- Motion – this is a resource waste. For example, are we asking support engineers to move physically in order to do parts of their job, for example go to the lab to recreate a problem? Are we requiring our employees to repeatedly switch contexts? For example, do we instruct support engineers to drop whatever they are doing to answer incoming phone calls?
- Waiting – this is another resource waste, where people or machine are idle due to lack of work or the need for another person’s knowledge or a constrained resource. Typical examples include access to systems needed to recreate a customer’s problem, access to a specialist with knowledge that can help make progress with a case and generally waiting for any other person or resource required to complete a task
- Over Processing – this is a work item waste, where the organization invests work that does not add customer value. For example, complicated forms acting as a barrier to escalations rather than facilitate rapid problem resolution, repeated analysis of a customer’s problem by multiple engineers and repeated attempts at fixing a customer’s problem or repeated repairs of returned equipment
- Over Production – this also is a work item waste. It usually refers to making items ahead of customer demand. A typical example could be preparing and publishing knowledge items for a one-time problem that will never be used again, or repairing products to be used to replace customers’ failed units in excessive quantities
- Defects – again a work item waste. It focuses on an end product that does not address a customer’s need. From providing the wrong fix through creating a knowledge item that misguides customers to hiring a person that’s not qualified to do the job
- Unused Employee Talent – I have written in the past about the impact of untapped employee talent from a knowledge management perspective. Additional examples include forcing escalations to happen within a certain time, even when the front line engineer has all the knowledge required to resolve the customer’s case
I am sure every reader can think of many other examples for wastes in their own environment. This post does not purport to provide an exhaustive list. Rather, it was an attempt to give readers a glimpse into the world of Lean as an additional tool to use for improving process flows. I hope you begin to make use of Lean thinking and that it works for you as well as it did for me