Lean Product and Process Design at Genoa

A couple of blogs back we shared the categories from the Lean Diagnostic Tool that will be used to measure the progress of Genoa's lean journey. An updated version of the diagnostic has categories added and some dropped. One of the categories added is Lean Product and Process Design.

Without detailing all of the steps or elements of this strategy, I'll attempt to describe how our path to Lean Product and Process Design (LPPD) will bring value to Genoa but more importantly to Genoa's customers.

We need to view the total effort of the work through to the actual fabrication of the ship in the yard and break out the effort in value streams:

1.) The Development Value Stream - The work Genoa does
2.) The Operational Value Stream - The fabrication work the customer does

Operational Value Streams are the result of Development Value Streams!!

Inherent in the Development Value Stream there are Operational Value Streams as well; that is, the steps Genoa does to provide deliverables to the customer. In order to ensure value for the customer, this value stream requires analysis to remove waste, improve lead times and quality, and add value for the customer. Most important in this analysis is to determine what value can be provided to the customer so that waste can be removed from the operational value stream before fabrication during the development and design phase. Remember the second line of Genoas mission statement ..."deliver waste-cutting work packs to clients". Genoa needs to ask itself, how can this be achieved.

Genoa can do this by ensuring that a number of events occur in the development phase;
- develop employee knowledge and sharing
- problem solve immediately, share results, and sustain improvements
- manage design flow by eliminating waste and variability
- standardize the design process
- design with assembly front of mind

Genoa needs to ensure that items within their control and influence make the customers operational value stream consistently profitable!!

In most manufacturing cases the owner of the development stream is the same as the owner of the operational stream. At Genoa the operational value stream owner is the customer. More importantly viewed as the partner in the effort. Everyone involved in the effort must work toward the success of the operational value stream which is the profit making stream.

I look forward to the day when we form a team with a partner towards this end. Right now it would be unfair to state that Genoa and it's clients operate independently because I see a lot of examples of cooperation and teamwork. I will say, that to achieve true excellence, there needs to be an effort where both value streams are viewed as one.

Ken Hogan
Lean Guy at Genoa

Before signing off, I'd like to introduce one of our designers..Brian Newhook. Brian is in his fourth year with Genoa and is responsible for most of the pictures of Newfoundland scenery on Genoas website http://www.genoadesign.com . Brian loves to kayak and his weekend activities have taken him to some spectacular places including very close to some amazing icebergs. Check this out. http://www.newfoundlandseakayaking.blogspot.com/