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Created On: 01/16/2020 05:49 AM
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01/20/2020 10:49 AM
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JeremyG
Jeremy G



G'day!

I am to evaluate lean implementation programs across several distinct organizations within the same company.

The objective is to paint an accurate picture of their respective setup, their lean training, the KPI used and other topics yet to be explored.

To avoid reinventing the wheel I would like to know if such Lean maturity Excel evaluation grid already exist. I have not been really successful in finding it online so far.

What questions would you include in such questionnaire if you were to do it? (I would like to be as exhaustive as possible)

Thank you!
01/28/2020 11:54 AM
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leanwannabe
Brian Koenig



SAE (Society of Automotive Engineers) published their J4000 Identification and Measurement of Best Practices in Implementation of Lean Operation back in 1998.

There's possibly better evaluations out there, but this defines about 50 criteria to evaluate Lean Implementation and should have some credibility as a source.

Here's a link to a preview of the first 10 criteria. Cost for a downloadable copy appears to be $83)

Good Luck

Brian


https://www.sae.org/standards/content/j4000_199908/preview/
01/28/2020 11:54 AM
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Ferdi
Ferdinand Huber



Hello Jeremy, I have done Lean Assessments for quite a few years in the automotive and Machinery industries. There are some key dimensions on how you can cluster your Questions. Check what is your Focus Area. You Need to define which area specific you are Focusing, is it the usage of lean Tools, material flow, Mindset, Leadership, CIP, ..? I would recommend you to define These dimensions first before defining the questions. Examples of dimensions are: Just-in-time, Quality, Continuous improvement, Problem solving, Standardization, Human resources, KPI's, Lean Awareness, Lean Tools, Lean Principles, Lean Leadership, Supply Chain, ... You could define 4 5 or 6 Dimensions for your organization and then define a set of Questions and Rating criteria.
01/28/2020 05:45 PM
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Carla_Kimberlin
Carla Kimberlin



Hi Jeremy-
Here is a Best Practices Mini-Assessment that I have seen used in the past. Of course, the scoring parameters could (should) change based on company goals. Perhaps this will help get you started. Good luck!

LEAN MANUFACTURING
Best Practices Mini-Assessment
Great companies strive to reduce waste, increase flexibility, and decrease lead times while still providing their customers with high-quality products by employing a variety of lean manufacturing techniques.
A: Our company's sales per employee (total sales divided by number of full time employees):
1: Not Measured 4: $200k - 300k
2: <$100k 5: >$300k
3: $100k - 200k

B: The number of times our inventory turns over per year:
1: Not Measured 4: 11 - 15
2: 1 - 5 5: >15
3: 6 - 10

C: Our percent of on-time deliveries:
1: Not Measured 4: 91% - 95%
2: <85% 5: >95%
3: 85% - 90%

D: Our product passes quality checks the first time through this percentage of the time:
1: Not Measured 4: 91% - 95%
2: <85% 5: >95%
3: 85% - 90%

E: The time to change-over our key process measured from last good piece to first good piece of next product:
1: Not Measured 4: 30 - 55 minutes
2: >2 hours 5: <30 minutes
3: 1 - 2 hours

F: The percentage of unplanned downtime of key equipment:
1: Not Measured 4: 10% - 19%
2: >30% 5: <10%
3: 20% - 30%

G: The percentage of product lines that are set up to manufacture product with minimal WIP between steps:
1: Not Measured 4: 51% - 75%
2: <25% 5: >75%
3: 25% - 50% H: Our workstations contain posted and updated standard work procedures:
1: Never 4: Usually
2: Seldom 5: Always
3: Sometimes

H: Our operators are cross-trained:
1: Never 4: Usually
2: Seldom 5: Always
3: Sometimes

I: Reduction in throughput time during the last year on our key product(s):
1: Not Measured 4: 11% - 15%
2: <5% 5: >15%
3: 5% - 10%

J: Our scrap rate:
1: Not Measured 4: 2% - 4%
2: >10% 5: <2%
3: 5% - 10%

K: We have visual controls (signs, pictures, procedures, etc.)
in place at this percentage of our workstations:
1: Not Measured 4: 51% - 75%
2: <25% 5: >75%
3: 25% - 50%

L: The number of suggestions implemented per employee per year:
1: Not Measured 4: 6 - 10
2: <2 5: >10
3: 2 - 5

M: Dedicated continuous improvement (Kaizen) events held per year:
1: Not Measured 4: 6 - 10
2: <2 5: >10
3: 2 - 5

N: The percentage of on-time delivery from our major suppliers:
1: Not Measured 4: 81% - 90%
2: <70% 5: >90%
3: 70% - 80%

O: Equipment currently covered by a Total Productive Maintenance program
1: Not Measured 4: 51% - 75%
2: <25% 5: >75%
3: 25% - 50%

P: The percent of product families for which the value stream has been mapped:
1: Not Measured 4: 51% - 75%
2: <25% 5: >75%
3: 25% - 50%

Q: The percent of plant areas that have a sustainable program for cleaning, sorting, and removing unused items/equipment and organizing remaining items using the 5S Methodology:
1: Not Measured 4: 51% - 75%
2: <25% 5: >75%
3: 25% - 50%

R: Our workforce is organized in empowered teams to address performance, quality, or safety issues:
1: Never 4: Usually
2: Seldom 5: Always
3: Sometimes

S: Team meetings are held:
1: Don't Know 4: Weekly
2: Annually 5: Daily
3: Monthly
01/28/2020 05:45 PM
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Robert_Simonis
Robert Simonis



Their are many Audits of Lean tools and they all leave a lot to be desired. I suggest the Shingo evaluation that focuses on behaviors, not paperwork or posters or tools
02/05/2020 03:28 PM
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JeremyG
Jeremy G



Hello

Thanks for your reply. I will finally focus on the following dimensions:

Strategy (example: is there any Lean strategy?)
Training (type of training, certifying, etc.)
Standards, tools
Benefits (financial and non financial ones)
Organization (structure in place)
Synergy (with other organization of the same group including best practice sharing)
02/05/2020 03:28 PM
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SaifArshad
Saif Arshad



This looks very helpful. Do you know if something like this exists for a non-manufacturing setup?
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