# Lean Methodology
- Originally used as **Lean Manufacturing** used by Toyota. Remove waste in each
phase, so that only value is added.
- Implement Lean project management when you want to use ==limited resources,
reduce waste, and streamline processes== to gain maximum benefits.
> [!summary] 5 Principles of Lean
>
> 1. Define value
> 2. Map value stream
> 3. Create flow
> 4. Establish pull
> 5. Pursue perfection
## Fundamentals
- Eliminate Waste
- Look early and often for waste
- Anything that does not add value to the product/service
- Focus on business processes
- Mistake Proof your Processes ([[poka-yoke|Poka-Yoke]])
- Create ways to eliminate any chance for error
- Physical restrictions, visual cues, templates, workflow order
- Processes should be "Pull", not "Push"
- Pull: determined by customer demand -- only provide what is required
- Push: determined by process -- produce what we "guess" will be needed (or our forecast!)
- Defects are not made and/or passed along
- Defects are prevented whenever possible, but never moved to the next step in the process
- Level & Balanced
- Workload design based on demand (tact time)
- Minimize non-value-added steps
- Multi-skilled employees perform more than one task
## Wastes
- **Intellect:** Failure to fully utilize the time and talents of people; lack of training
- **Motion:** Any motion that does not; add value; chasing parts, signatures, tools, etc
- **Defects:** Any rework; errors
- **Overproduction:** Producing too much; producing too soon; batch processing
- **Extra Processing:** Adding inspections; approvals; reviews
- **Transportation:** Any nonessential transport or handling
- **Inventory:** High supply stores; finished product stores; in-work materials
- **Waiting:** Waiting on parts or documents, waiting for other workers or a machine
## Lean Tools
- [[5s|5S]]
- [[value-stream|Value-Stream Mapping]]
- [[kaizen|Kaizen]] -- Kaizen Blitz/Event
- Simplification
- Pull/[[kanban|Kanban]]/2-Bin System
- Visual Controls
- Error-Proofing ([[poka-yoke|Poka-Yoke]])
- Set-up Reduction
- Total Productive Maintenance
- Standard Workd
- Gemba Walks
- Leader Standard Work
## Challenges
- Buy-in from entire team
- Current attitudes
- Trust as a core building block
- Future commitments
- Sustaining gains
- Continuing to improve
- Cultural change