LEAN BREAKFAST ANALOGY

BASIC PRINCIPLES OF LEAN BREAKFAST ANALOGY

1.

Basic Lean Principles

6S / Visual Workplace One-Piece Flow / Pull System Standardized Work Waste Reduction Lead Time Reduction / Concurrent Processes Modular Design / Delayed Differentiation Error-Proofing / Poka-Yoke

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1) 6S / Visual Workplace

Storing the butter in the Butter Tray, eliminates search time through Refrigerator.

Butter Tray in Refrigerator is clearly labeled Tray is appropriately sized to store butter Tray is see through, gives visual signal when supply is running low

A place for EVERYTHING, and EVERYTHING in its place 2

2) One-Piece Flow / Pull System

Buying one gallon of milk at a time, to avoid inventory becoming obsolete (expiring).

Gallon of milk acts as one-piece flow, gives visual signal when milk level in container reaches Reorder Point Avoid stocking up at grocery store just because of Supplier Discount Gallon moves in First In First Out method (FIFO), where the oldest gallon is consumed first. This ensures no inventory becomes obsolete

Inventory is not pushed downstream, but rather PULLED from customer as soon as it is needed 3

3) Standardized Work

Follow Cinnamon Roll baking instructions (Work Instructions) on package.

If operator is free to follow instructions in any order, may apply icing before rolls are baked in oven instead of afterwards Results in damaged product (icing is burnt, creates smoke, creates mess in oven and on baking sheet)

All elements of a work process are STANDARDIZED and DOCUMENTED, so any trained operator can perform them in a SAFE, EFFICIENT, PREDICTABLE manner 4

4) Waste Reduction

Use cooking spray on pan before cooking eggs.

Performing tasks in a smart, organized manner can prevent wasted efforts downstream Using cooking spray before cooking will prevent eggs from sticking to pan Waste of Rework having to cook the eggs again Waste of Waiting - needing to let pan soak before cleaning Waste of Overprocessing spending non-value added time scrubbing pan The 9 Wastes of Lean DOWNTIMEE 1. 2. 3. 4. 5.
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Defects Overproduction Waiting Non-Utilized Talen Transportation

6. 7. 8. 9.

Inventory Motion Extra Processing Energy Inefficiency

Any items or processes that the Customer is not willing to pay for are eliminated

5) Lead Time Reduction / Concurrent Processes

Brewing coffee while cooking eggs.

Brewing a pot of coffee has shorter cycle time than cooking eggs Coffee requires little manual intervention C/T of cooking eggs can fit concurrently within L/T of brewing coffee
L/T = 8 min L/T = 5 min

C/T = 3 min

C/T = 5 min
startC

BREW COFFEE COOK EGGS

BREW COFFEE
startC finishC startE

COOK EGGS
finishE startE

finishC
finishE

One of the best ways to reduce Lead Time, avoiding spending for Capacity, is to eliminate WASTE 6

6) Modular Design / Delayed Differentiation

Plain yogurt with fruit flavor packet add-ins.

Retailer and Customer can stock less inventory/SKUs, and have the same amount of options Avoid bulk buying to get a variety of choices Less capital/storage space tied up in inventory

Common components should be used in product design wherever feasible, and varieties of a product should be created as far downstream as possible 7

7) Error-Proofing / Poka-Yoke

Eliminating errors through automation.

Prevention: Using an egg strainer to separate the egg white from the yolk Automatic Detection: Toaster senses how cooked a piece of bread is, will shut off when desired level is reached Manual Inspection: When bacon stops curling, it is cooked

Automatic error-proofing should be implemented wherever feasible. The next best approach is to immediately monitor the output and detect if it goes out of spec" 8