WIP Archive

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Looking for Lean in Inefficient Processes

first-class forever stampThis morning, I wrote a physical check and placed it into a physical envelope. I hand-wrote the addresses on the envelope and even put a physical stamp on it.  I will mail it, when I take my semiweekly trip to the mailbox.  This is the first time I can remember doing this in a few years.  The party recieving my payment is forcing me to follow this inefficient business process of mailing a physical payment to them.  All I can think is how this used to be the norm and now how ridiculously inefficient it appears.

When objectively judging the efficiency of this process, I started by first measuring two things, the Work-in-Process (WIP) and the Average Completion Rate (ACR).

Little’s Law

This law provides an equation for relating Lead Time, Work-in-Process (WIP) and Average Completion Rate (ACR) to any process. The law states: Lead Time = WIP (units) / ACR (units per time period).  The idea is to have the lowest lead time as possible.  Lower lead times means less waste.

Am I the only geek out there who does this?  Where do you see inefficient processes that could benefit from a more lean approach?

 

 

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Theme Park Pull System

Roller Coaster LineIf you’ve been to a theme park like Disney World’s Magic Kingdom or Hollywood Studios, you will quickly notice the lines.  Depending on the time of year (or day) the line to a ride or attraction could be anywhere from nonexistent to 90+ minutes long.  As you approach an entrance, you’ll see a line marked on the grounds and a sign that reads “N minutes from this point”. You want the sign to read 5 minutes.  That’s the time it takes, with no wait line, to get to the actual attraction.  What you don’t see from the line on the ground is the maze of lines snaking their way through the building.  If the volume of people is low, everything except the direct line to the attraction is roped off.  The more the people, the more “side” lines are open.  The line outside the attractions are deceasing.  The real delays start after you cross that line marked on the ground and are committed.

I noticed that attractions usually lasted less than 5 minutes and people were divided into groups, just prior to onboarding some kind of transportation.  The transportation ran at a consistent rate of speed.  All these factors included, Disney World has to know the maximum throughput of a ride, before the line starts to back up. Why do you ask?  Well, to keep the customer happy by keeping them moving, of course.

When I saw all of this happening, I thought it was an excellent example of a pull system.  We went on a ride called “Star Tours”.  The vehicle capacity was 40 people and the ride duration was 4:30 minutes.  We noticed the sign said 90 minutes from this point.  Can you imagine doing that with a 5-year-old?

Star Tours
Capacity=40 people per load
Lead Time=90:00 minutes
Actual Duration=4:30 minutes

So, what does Disney do to help resolve the issue?  They call it the Fast Pass.  Yes, the golden ticket.  When you see the line at its worst, go up to a kiosk and get a Fast Pass.  It will tell you to return to the ride at a designated time.  In exchange for doing that, it will allow you to go to the head of the line, when that time comes.  I am assuming they are having you return at a predicted time of day in which the line will be shorter.  Regardless, it eliminated the bottleneck for us.  Whenever we saw a hellish line, we got a Fast Pass and came back later in the day.

To prevent the Fast Pass people from completely stopping the line, it appeared a certain percentage of seats per load were allocated for Fast Pass ticket holders.

I think this Fast Pass option may also work with non-theme park customers.  Let’s say you are working on an application development project.  After you have an optimum cycle time, if you reserve a little capacity, you could potentially negotiate with a stakeholder to postpone an activity to a date or time in which you know the workload will be less.  I’m not saying you are postponing adding the work to your backlog.  It’s still there.  But, you could agree to make it a lower priority until more of the backlog gets completed.  This could keep the rest of the work moving at an optimum pace and keep the customer happy.

Drawing by Pictofigo

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I Got a Feeling

I was sitting at my desk when this song by the Black Eyed Peas called “I got a feeling” came on Pandora.  My son rushed over yelling to turn it up. I attribute turning up the volume to the resulting earworm that has lasted the last few days.  There could be worse things in the world.  Each time I hear it, I think of the flash mob that danced in Chicago for Oprah.  It amazes me how so many (strangers) came together to create something that brings a smile to my face every time I see the video.

As I was preparing for day zero for LitheSpeed (I don’t officially start until tomorrow), I found myself singing the song and thinking about “the feeling”.   After taking a week off, I was able to break the cycle that had me feeling a bit numb for so long.  Just a few weeks ago, I felt like I was trying to keep control of an uncontrollable situation.  That can become exhausting.  But today I felt completely different.  This morning I felt excited about what I was about to do.  I felt an entrepreneurial drive I haven’t felt for a long time.  It’s that feeling when you play offense not defense.

Tomorrow is day one.  I have my Kanban loaded.  I have my WIP limited.  I got a feelin’ tomorrow is gonna be a good day.  Let’s do it.

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Reading about Process Improvement

Reading Books Over the weekend, I found myself trying to read a physical book about systems analysis while listening to a book on operational process improvement.  I’m not going to go into the physical book because I am so impressed with the audio book.  I guess it wouldn’t matter if it was physical, digital, or audio.  It’s just a really really good book!

It’s titled: The Goal: A Process of Ongoing Improvement by Eliyahu M. Goldratt (yes, if someone clicks on that link and buys a book, I would get credit)

Though the story reads like fiction, in its introduction of characters and story, it does an amazing job of introducing concepts to the reader.  The main character manages a production plant, where everything is always behind schedule and things are looking pretty bad. (Sound like any projects you know?)  The production plant is doing so poorly, the company has given the main character an ultimatum.   With a threat of closure, the plant has three months to turn operations from being unprofitable and chronically late on deliveries to being profitable and successful.  In the book, we are introduced to the Socratic method. Throughout the book, a character poses questions to another or a member of a team, which in turn causes them to talk amongst themselves to come up with a solution to their problem.

Because the book revolves around manufacturing and not application development or project management, there are a few dotted lines that need to be drawn.  But, overall, it really got my wheels spinning.  It doesn’t matter if you’re using Kanban or if you’re in any type of management position, I would recommend this book.

One quote really stuck with me

Intuitive conclusions (common sense) are commonly masked by common practice

Process Improvement

The following lists some of the ways that processes can be improved.

  • Reduce work-in-process (WIP) inventory to reduce lead time
  • Add additional resources to increase capacity of the bottleneck
  • Improve the efficiency of the bottleneck activity to increase process capacity
  • Move work away from bottleneck resources where possible to increase process capacity
  • Increase availability of bottleneck resources to increase process capacity
  • Minimize non-value adding activities to decrease cost and reduce lead time

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Valentine’s Day Pull System

fondue - pull systemNothing is quite as romantic as sitting with your husband or wife, sharing a dinner of fondue.  Nothing, that is, unless you’re sitting with me.  I’m not a big fondue guy.  This is sad because my wife loves it.  She enjoys the whole process.  To counter that, I like my food to be given to me, already prepared.  I enjoy the results!

So, leave it to me to point at the fondue pot half way through dinner and yell “Fondue is a pull system!  Fondue is a pull system!”

What is a pull system you ask?  Perhaps you’ve heard of Drum-Buffer-Rope or Kanban?

Businessdictionary.com defines it as a Manufacturing system in which production is based on actual demand, and where information flows from market to management in a direction opposite to that in traditional (push) systems.

The idea behind a pull system is to keep a smooth production flow.  For the sake of argument, let’s say N is a volume of work output.  It can be trouble-ticket call volume, software development, or hardware manufacturing.  Any of these work in the example.  If you and your team can consistently deliver quality N in a month, and keep a good work-life balance, you should know that a C-Level executive asking you to deliver N+10 is going to create bottlenecks in your process flow.  Your overall delivery velocity is going to slow and your team is going to work longer hours trying to deliver N+10.  This increase is unsustainable unless something changes.  You need to get back to N, either by cutting back the work, expanding the amount of people or things to complete the work, or find some efficiencies.

You limited your work in progress (WIP) for a reason!  If more is going into your process than is coming out, you’re going to accumulate a backlog.  For every unit exiting your process, you should have another unit ready to enter it.

For fondue, you limit your work in progress by the amount of long-stemmed forks you have to put into the pot (caquelon).  Before you start, you cut up all of your fruits, vegetables, meats…whatever you plan to dip.  That’s your product backlog.  You then begin dipping whatever you have, X at a time.  We had 3 forks each.  When the food is done, you take it off the fork, add another piece of food, and back into the pot it goes.  You can’t eat anything until it’s done with the process.

Am I a romantic buzz kill or what!?

Image: Recipe Tips

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