What is Lean Thinking?
         A systematic approachto identifying and
           eliminating waste through continuous improvement
           by flowing the service or product at the pull
            of customers in pursuit of perfection.
       Process
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       Coaching                                  © 2008 Process Coaching Incorporated
       Incorporated
                  History of Lean Manufacturing
                                                                         1950’s - Taiichi 
                             1920’s                                      Ohno develops the 
                             Sakichi Toyoda                              Toyota Production 
                             develops mistake        August 4, 1937      System (TPS)
     1798                                            First supermarket 
    Eli Whitney develops     proofing  and 5 Whys    in the United 
    interchangeable                                  States opened
    parts
                                                              June – August 1950
      1908 through 1913                                       Deming introduces lean 
      Henry Ford develops              1933 - Toyota          quality principles to 
      the moving assembly              Motor Company          Japanese engineers and 
      line.                            established            managers
         Process
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         Coaching                                                   © 2008 Process Coaching Incorporated
         Incorporated
           House of Lean
      Process
                                                     Page 4 of 46 
      Coaching                            © 2008 Process Coaching Incorporated
      Incorporated
             Benefits of Lean Production
              Reduction in overhead / operating costs 
              Productivity Increase (30% - 40%)
              Throughput Time Decrease (70% +)
              Increase Profit
              Customer Lead Time Reductions (50% +)
              Work in Process Inventory reductions (70%+)
              On Time Delivery to customers (95% +)
              Quality Performance Improvements
      Process
                                                          Page 5 of 46 
      Coaching                                 © 2008 Process Coaching Incorporated
      Incorporated
            The Eight Deadly Wastes
       Overproduction            Excess Inventory
       Waiting                   Defects
       Transportation (Moving)   Excess Motion
       Non-Value Added           Underutilized Resources
        Processing
      Process
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      Coaching                             © 2008 Process Coaching Incorporated
      Incorporated