Kanban Lean Manufacturing Process Optimization
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The document discusses Kanban and how it can be applied to both manufacturing and knowledge work. It uses an example of a wheel factory to illustrate Kanban concepts like limiting work in process, visualizing the flow of work, and continuous improvement. Kanban aims to eliminate waste from processes by continuously evolving processes based on feedback, using small incremental changes rather than large transformations.
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Kanban Lean Manufacturing Process Optimization
- 1. @jonathansen Done Develop DoneAnalysis Testing Ready for DemoOngoing DoneOngoing Sprint Backlog DoneOngoing F C H D I E E G A B J K L (3) (2) Jonathan Hansen Thumbtack Technology Introduction to Kanban for Scrum Teams
- 2. @jonathansen Growing Beyond Scrum Helping Scrum Delivery What is Kanban? Intro Topics (4) Discussing (1) To Review (3) Done
- 3. @jonathansen Growing Beyond Scrum Helping Scrum Delivery What is Kanban? Intro Topics (4) Discussing (1) To Review (3) Done
- 4. @jonathansen JUST DO WHATEVER •Fragile Produc5on System •Chao5c Execu5on •Coordina5on with Large Staff •Miscommunica5on with Business Old Methodology at my Startup
- 6. @jonathansen •GeFng Started with Scrum •Actually Finishing Work •Managing Unbreakable Epics Kanban Enables Scrum Prac5ces
- 7. @jonathansen Kanban Improves Scrum Prac5ces •Daily Standups •Sprint Planning •Delivery Cadences
- 8. @jonathansen Growing Beyond Scrum Helping Scrum Delivery What is Kanban? Topics (4) Discussing (1) To Review (3) Done Intro Lean Manufacturing Knowledge Work Kanban Method
- 9. @jonathansen A POPULAR PREFIX • Lean Kanban • Lean Startup • Lean UX • Lean In • Lean Manufacturing • Lean Six Sigma • Lean Thinking • Lean Enterprise • Lean Analy5cs • Lean Branding • Lean Healthcare • Lean Educa5on • Lean Cuisine • Lean SoRware Development • Lean Coffee
- 10. @jonathansen LEAN ConEnuously Improve how you Eliminate Waste that prevents the delivery of the correct, high quality products to customers when they need them.
- 11. @jonathansen TITLE TEXT Traditional Lean Financial Strategy Economics of Scale Less Upfront Cost Production Strategy Push Pull Defect Strategy Quan5ty Quality
- 12. @jonathansen + = Western Wheel Factory Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly +Process: 15/hour 10/hour HOUR 1 START
- 13. @jonathansen Western Wheel Factory HOUR 1 END Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly •Wasted Effort •Worse over Time
- 14. @jonathansen Western Wheel Factory HOUR 2 START Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly
- 15. @jonathansen Western Wheel Factory HOUR 2: END Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly
- 16. @jonathansen Western Wheel Factory HOUR 4: START Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly
- 17. @jonathansen Western Wheel Factory HOUR 4: END Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly
- 18. @jonathansen Western Wheel Factory HOUR 6: START Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly
- 19. @jonathansen Western Wheel Factory HOUR 6: END Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly •Work Pushed through Process Based on Plan •Inventory piles up to be dealt with later
- 20. @jonathansen TITLE TEXT Traditional Lean Financial Strategy Economics of Scale Less Upfront Cost Production Strategy Push Pull Defect Strategy Quan5ty Quality
- 21. @jonathansen Western Wheel Factory Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly DEFECT APPROACH 1.Defects Discarded 2.Replaced with Inventory Defect
- 22. @jonathansen Western Wheel Factory Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly DEFECT APPROACH 1.Defects Discarded 2.Replaced with Inventory
- 23. @jonathansen Western Wheel Factory Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly DEFECT APPROACH 1.Defects Discarded 2.Replaced with Inventory
- 24. @jonathansen TITLE TEXT Traditional Lean Financial Strategy Economics of Scale Less Upfront Cost Production Strategy Push Pull Defect Strategy Quan5ty Quality
- 25. @jonathansen KANBAN IN MANUFACTURING The system for limiEng excessive Work in Process
- 26. @jonathansen •Limited Number of Produc3on kanban cards •Card means “Make me an item” •Without a card, nothing gets built •Limited by Customer Demand •Limited by Produc3on Capability Lean Wheel Factory Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly WW WW WW WW WW
- 27. @jonathansen •Limited Number of Produc3on kanban cards •Card means “Make me an item” •Without a card, nothing gets built •Limited by Customer Demand •Limited by Produc3on Capability Lean Wheel Factory Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly WW WW WW WW WWHR HR HR HR HR HR HR HR HR HR
- 28. @jonathansen Lean Wheel Factory KANBAN CARD = START ASSEMBLING HR HR HR HR HR HR HR HR HR HR Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly WW WW WW WW WW
- 29. @jonathansen Lean Wheel Factory KANBAN CARD = START ASSEMBLING HR HR HR HR HR HR HR HR HR HR Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly WW WW WW WW WW Hub Bin
- 30. @jonathansen Lean Wheel Factory KANBAN CARD = START ASSEMBLING HR HR HR HR HR HR HR HR HR HR Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly W WW WW WW WW W
- 31. @jonathansen Lean Wheel Factory PART CONSUMED = CARD SET ASIDE HR HR HR HR HR HR HR HR HR HR Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Final Wheel Assembly WW WW WW WW WW Wheel Bin
- 32. @jonathansen Lean Wheel Factory HR HR HR HR HR HR HR HR HR HR Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Final Wheel Assembly W W WW WW WW WW Wheel Bin
- 33. @jonathansen Lean Wheel Factory HR HR HR HR HR HR HR HR Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Final Wheel Assembly W W WW WW WW Wheel Bin HR HRW W
- 34. @jonathansen Lean Wheel Factory HR HR HR HR HR HR Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Final Wheel Assembly W W WW WW HRHR W W Wheel Bin HR W HR W
- 35. @jonathansen Lean Wheel Factory HR Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Final Wheel Assembly HRHR Wheel Bin HRHRHR WW W WW W W WW W HRHRHR HRHRHR Only requests parts needed
- 36. @jonathansen TITLE TEXT Traditional Lean Financial Strategy Economics of Scale Less Upfront Cost Production Strategy Push Pull Defect Strategy Quan5ty Quality
- 37. @jonathansen 1.Stop the Line 2.Discover Problem Cause 3.Experiment to Prevent Problem in Future Lean Wheel Factory HR HR HR HR HR HR HR HR HR Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Final Wheel Assembly W WW WW WW WW Wheel Bin DEFECT APPROACH HR W
- 38. @jonathansen 1.Stop the Line 2.Discover Problem Cause 3.Experiment to Prevent Problem in Future Lean Wheel Factory HR HR HR HR HR HR HR HR HR Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Final Wheel Assembly W WW WW WW WW Wheel Bin DEFECT APPROACH HR W
- 39. @jonathansen LEAN QUALITY APPROACH • “Stop the Line” • Everybody’s problem • Small Changes • Con5nuous Changes
- 40. @jonathansen “Toyota makes millions of improvements every year, all generated from the ideas of their employees world wide” -‐ Paul A. Akers
- 41. @jonathansen LEAN ConEnuously Improve how you Eliminate Waste that prevents the delivery of the correct, high quality products to customers when they need them.
- 42. @jonathansen Growing Beyond Scrum Helping Scrum Delivery What is Kanban? Topics (4) Discussing (1) To Review (3) Done Intro ☑Lean Manufacturing Knowledge Work Kanban Method
- 43. @jonathansen Western Wheel Factory Hub Bin Rim Bin Hub+Rim Assembly Tire BinH+R Bin Wheel Bin Final Wheel Assembly This happens in our brains and we don’t even see it
- 44. @jonathansen MENTAL WIP EXERCISE 1. Fibonacci: Fn = Fn-‐1 + Fn-‐2 (1, 1, 2, 3, 5,…) 2. Sevens (7, 14, 21,…) 3. Alphabet (A, B, C,…) 4. Roman Numerals (I, II, III, IV,…)
- 47. @jonathansen Lean ChangeCapability Time Smaller Changes Improvement Never Ends Each Change Less PainfulEarly Success Feedback
- 48. @jonathansen KNOWLEDGE WORK • Inventory is in your Head • Myth of Mul5tasking • Resist Big Change
- 49. @jonathansen Kanban Method by David Anderson Evolu3onary Change Management Method Because Change is Scary
- 50. @jonathansen Kanban Method Principles 1. Start with what you do now 2. Agree to Evolu3onary Change 3. Ini3ally, don’t change job 3tles, roles, responsibili3es
- 51. @jonathansen KANBAN METHOD PRACTICES 1. Visualize the Work Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M
- 52. @jonathansen KANBAN METHOD PRACTICES 1. Visualize the Work Source: 3founders.com
- 53. @jonathansen KANBAN METHOD PRACTICES 2. Limit Work in Process Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4) Upstream of Bottleneck Bojleneck
- 55. @jonathansen KANBAN METHOD PRACTICES 3. Manage Flow Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4) But what if a Dev is free?!?
- 56. @jonathansen KANBAN METHOD PRACTICES 3. Manage Flow Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4) But what if a Dev is free?!? Some Op5ons: • Automate Tests • Refactor (if TDD) • Read a Book • Take a Nap
- 57. @jonathansen KANBAN METHOD PRACTICES 4. Make Process Policies Explicit Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4) “Code is wrijen!” “Code is wrijen + unit tests pass!”
- 58. @jonathansen KANBAN METHOD PRACTICES 4. Make Process Policies Explicit Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4) “Code is wrijen!” “Code is wrijen + unit tests pass!” Some Tips: • Write Lane Policies where Work Is • Add Sprint or Project Goal • Con5nuous Improvement: Policies change! • Update them
- 59. @jonathansen KANBAN METHOD PRACTICES 5. Implement Feedback Loops Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4) • Customer: Deliver Frequently • Team: Align on In Process Work • Team: Tweak Process to Improve It
- 60. @jonathansen KANBAN METHOD PRACTICES 5. Implement Feedback Loops Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4) • Customer: Deliver Frequently • Team: Align on In Process Work • Team: Tweak Process to Improve It Scrum Helps!
- 61. @jonathansen KANBAN METHOD PRACTICES 6. Improve Collaboratively, Evolve Experimentally Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4)
- 62. @jonathansen KANBAN METHOD PRACTICES 6. Improve Collaboratively, Evolve Experimentally Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4)
- 63. @jonathansen KANBAN METHOD PRACTICES 6. Improve Collaboratively, Evolve Experimentally Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4) “You are allowed to Think” -‐ Klaus Leopold
- 64. @jonathansen KANBAN METHOD PRACTICES 6. Improve Collaboratively, Evolve Experimentally Sprint Backlog Develop Test Ready to Demo Accepted K A B C D E F G H I J L M (3) (4) • Don’t get Hung up on Kanban Rules • Or Scrum Rules • If you think something will help, try it! • If it doesn’t work, try something else! “You are allowed to Think” -‐ Klaus Leopold
- 65. @jonathansen Kanban Method PracRces 1.Visualize Your Work 2.Limit WIP 3.Manage Flow 4.Make Process Policies Explicit 5.Implement Feedback loops 6.You are Allowed to Think
- 66. @jonathansen Growing Beyond Scrum Helping Scrum Delivery What is Kanban? Topics (4) Discussing (1) To Review (3) Done Intro ☑Lean Manufacturing ☑Knowledge Work ☑Kanban Method
- 67. @jonathansen Growing Beyond Scrum Helping Scrum Delivery What is Kanban? Topics (4) Discussing (1) To Review (3) Done Intro
- 68. @jonathansen Growing Beyond Scrum Helping Scrum Delivery What is Kanban? Topics (4) Discussing (1) To Review (3) Done Intro Meet Sprint Commitments Daily Standup An5pajerns Epic Management
- 69. @jonathansen Helping Scrum Delivery MEETING SPRINT COMMITMENTS Successful Sprint? 0 45 90 135 180 Without Kanban
- 70. @jonathansen Helping Scrum Delivery SPRINT DAY 1 Doing Done D5 S3 S4 D3 D4 E1E2 S2 D2 S1 D1 Search Detail Edit E3 E4 E5 SQA Blk DQA Blk EQA Blk Sprint Backlog Without Kanban
- 71. @jonathansen Helping Scrum Delivery SPRINT DAY 5 Sprint Backlog Doing Done D5 S3 S4 D3 D4 E1 E2 S2 D2 S1 D1 Search Detail Edit E3 E4 E5 SQA Blk DQA Blk EQA Blk Without Kanban
- 72. @jonathansen Helping Scrum Delivery SPRINT DAY 10 Sprint Backlog Doing Done D5 S3 S4 D3 D4 E1 E2 S2 D2 S1 D1 Search Detail Edit E3 E4 E5 SQA DQA EQA SB5 SB4 SB3 SB2 SB1 DB1 DB2 DB3 DB4 EB1 EB2 EB3 EB5 EB4 Without Kanban
- 73. @jonathansen Helping Scrum Delivery MEETING SPRINT COMMITMENTS Successful Sprint? 0 45 90 135 180 Without Kanban NOPE!
- 74. @jonathansen High Task WIP = Slow Tasks 0 10 20 30 40 Done Doing Todo Helping Scrum Delivery MEETING SPRINT COMMITMENTS Without Kanban AVG LEAD 3.7 DAYS AVG WIP 7.5 ITEMS
- 75. @jonathansen High Task WIP = Slow Tasks 0 10 20 30 40 Done Doing Todo Helping Scrum Delivery MEETING SPRINT COMMITMENTS Without Kanban AVG LEAD 3.7 DAYS AVG WIP 7.5 ITEMS Little’s Law
- 76. @jonathansen Helping Scrum Delivery MEETING SPRINT COMMITMENTS High Feature WIP = Idle QA + More Bugs 0 10 20 30 40 Done Doing Todo Without Kanban Scope Creep from 17 to 31 Tasks No Features Testable for 7 Days
- 77. @jonathansen Helping Scrum Delivery HELPFUL KANBAN PRACTICES With Kanban 1.Visualize the Work 2.Limit WIP (Features & Tasks) 3.Manage Flow
- 78. @jonathansen E2 E1 Helping Scrum Delivery SPRINT DAY 1Doing Done D5 S3 S4 D3 D4 S2 D2 S1 D1 Features Tasks E3 E4 E5 Sprint Backlog With Kanban (2) (4) Search Detail Edit Development Testing
- 79. @jonathansen E2 E1 Helping Scrum Delivery SPRINT DAY 5Doing Done D5 S3 S4 D3 D4 S2 D2 S1 D1 Features Tasks E3 E4 E5 Sprint Backlog With Kanban (2) (4) Search Detail Edit Development Testing SB4 SB3 SB2 SB1
- 80. @jonathansen E2 E1 Helping Scrum Delivery SPRINT DAY 10Doing Done D5 S3 S4 D3 D4 S2D2 S1 D1 Features Tasks E3 E4 E5 Sprint Backlog With Kanban (2) (4) Search Detail Edit Development Testing SB4 SB3 SB2 SB1DB1 DB2 EB1EB2 EB3 EB4
- 81. @jonathansen Helping Scrum Delivery MEETING SPRINT COMMITMENTS Scrum Alone 0 10 20 30 40 AVG LEAD 3.7 DAYS AVG WIP 7.5 ITEMS Scrum + Kanban 0 10 20 30 40 AVG LEAD 0.5 DAYS AVG WIP 1.4 ITEMS
- 82. @jonathansen Helping Scrum Delivery MEETING SPRINT COMMITMENTS Scrum Alone 0 10 20 30 40 AVG LEAD 3.7 DAYS AVG WIP 7.5 ITEMS Scrum + Kanban 0 10 20 30 40 AVG LEAD 0.5 DAYS AVG WIP 1.4 ITEMS No QA 7 Days 17 to 31 Tasks QA in 4 Days 14 to 24 Tasks
- 83. @jonathansen Helping Scrum Delivery MEETING SPRINT COMMITMENTS Comparing Burndowns 0 45 90 135 180 Scrum Alone Scrum with Kanban
- 84. @jonathansen Growing Beyond Scrum Helping Scrum Delivery What is Kanban? Topics (4) Discussing (1) To Review (3) Done Intro ☑Meet Sprint Commitments Daily Standup An5pajerns Epic Management
- 86. @jonathansen Daily Standup An5pajerns •Digging Deep •No Accountability •Upda5ng the PM
- 87. @jonathansen Done Lean Daily Standups WALK THE BOARD With Kanban Develop Done F C H D I J E G A B Backlog Testing Deploy- ment(10) (2)(3) (1)Ongoing DoneOngoing What do we need to do to deploy B?
- 88. @jonathansen Growing Beyond Scrum Helping Scrum Delivery What is Kanban? Topics (4) Discussing (1) To Review (3) Done Intro ☑Meet Sprint Commitments ☑Daily Standup An5pajerns Epic Management
- 89. @jonathansen Epic Management WORST SPRINT DEMO EVER
- 90. @jonathansen Done Epic Management UNSPLITTABLE FEATURES With Kanban Develop Done F C H D I E E G A B Backlog Testing Ready for Demo (2)(3) Ongoing DoneOngoing Not Sprint Sprint Next Up (10) (2) J K L
- 91. @jonathansen What is Kanban? Topics (4) Discussing (1) To Review (3) Done Helping Scrum Delivery Growing Beyond Scrum Intro
- 92. @jonathansen What is Kanban? Topics (4) Discussing (1) To Review (3) Done Helping Scrum Delivery Growing Beyond Scrum Intro“In Scrum, you should inspect and adapt on everything... except Scrum.” -‐ David J. Bland haps://twiaer.com/davidjbland/status/430769613903654912
- 93. @jonathansen What is Kanban? Topics (4) Discussing (1) To Review (3) Done Helping Scrum Delivery Growing Beyond Scrum Intro Lean Sprint Planning Kill the Timebox Ques5on Everything
- 94. @jonathansen Lean Sprint Planning ARE YOU GETTING STORY POINT ACCURACY? 0 25 50 75 100 Actual Days to Complete 1 2 3 4 5 6 7 8 9 10 2-‐Point 3-‐Point
- 95. @jonathansen Lean Sprint Planning STORY POINT ALTERNATIVE: HISTORICAL LEAD TIME 0 10 20 30 40 4/6/15 4/14/15 4/23/15 5/2/15 5/11/15 upper limit: 29.88 mean: 5.94
- 96. @jonathansen Lean Sprint Planning HISTORICAL LEAD TIME: HISTOGRAM 0 3.5 7 10.5 14 Actual Days to Complete < 1 day 1 to 5 5 to 10 10 to 20 > 20
- 97. @jonathansen Lean Sprint Planning HISTORICAL LEAD TIME: HISTOGRAM network 0 1.25 2.5 3.75 5 Actual Days to Complete < 2 2 to 6 6 to 10 > 10 UI 0 1 2 3 4 Actual Days to Complete < 1 1 to 2 2 to 6 > 6
- 98. @jonathansen Lean Sprint Planning FEATURE ESTIMATION ALTERNATIVE 1.Study Historical Data 2.Categorize Cards 3.Calculate Ranges 4.Shape Sprint
- 99. @jonathansen What is Kanban? Topics (4) Discussing (1) To Review (3) Done Helping Scrum Delivery Growing Beyond Scrum Intro ☑Lean Sprint Planning Kill the Timebox Ques5on Everything
- 100. @jonathansen Done Develop DoneAnalysis Testing Ready for DemoOngoing DoneOngoing Sprint Backlog DoneOngoing Killing the Timebox F C H D I E E G A B J K L (3) (2) Avg cycle: 3 days Avg Lead: 32 days
- 101. @jonathansen Done Develop DoneAnalysis Testing Ready for DemoOngoing DoneOngoing Sprint Backlog DoneOngoing Killing the Timebox F C H D I E E G A B J K L (3) (2)
- 102. @jonathansen Done Develop DoneAnalysis Testing Ready for DemoOngoing DoneOngoing Priorities DoneOngoing Killing the Timebox F C H D I E E G A B J K L (3) (2) (10) Avg cycle: 3 days Avg Lead: 32 days14
- 103. @jonathansen Done Develop DoneAnalysis Testing Deploy Ongoing DoneOngoing Priorities DoneOngoing Killing the Timebox F C H D I E E G A B J K L (3) (2) (10) (2) Avg cycle: 3 days Avg Lead: 14 days7
- 104. @jonathansen
- 105. @jonathansen Our goal is not Scrum or Kanban. Our goal is to make sure we’re doing everything we can to meet the needs of our customers, team members, and stakeholders. And to keep doing it when those needs change.
- 106. @jonathansen What is Kanban? Topics (4) Discussing (1) To Review (3) Done Helping Scrum Delivery Growing Beyond Scrum Intro
- 107. @jonathansen Intro What is Kanban? Topics (4) Discussing (1) To Review (3) Done Helping Scrum Delivery Growing Beyond Scrum
- 108. @jonathansen Intro What is Kanban? Topics (4) Discussing (1) To Review (3) Done Helping Scrum Delivery Growing Beyond Scrum Your QuesEons
- 109. @jonathansen Intro What is Kanban? Topics (4) Discussing (1) To Review (3) Done Helping Scrum Delivery Growing Beyond Scrum Your QuesEons
- 110. @jonathansen Intro What is Kanban? Topics (4) Discussing (1) To Review (3) Done Helping Scrum Delivery Growing Beyond Scrum Your QuesEons Introduction to Kanban for Scrum Teams Jonathan Hansen Thumbtack Technology