{"id":13456,"date":"2021-06-25T00:00:00","date_gmt":"2021-06-25T04:00:00","guid":{"rendered":"https:\/\/lei.flywheelsites.com\/the-lean-post\/articles\/how-synchronizing-workflows-eliminates-waste-in-development-processes\/"},"modified":"2023-11-13T10:43:53","modified_gmt":"2023-11-13T15:43:53","slug":"how-synchronizing-workflows-eliminates-waste-in-development-processes","status":"publish","type":"post","link":"https:\/\/www.lean.org\/the-lean-post\/articles\/how-synchronizing-workflows-eliminates-waste-in-development-processes\/","title":{"rendered":"How Synchronizing Workflows Eliminates Waste in Development Processes"},"content":{"rendered":"\n<p><em>Be among the first to get the latest insights from LEI&#8217;s Lean Product and Process Development (LPPD) thought leaders and practitioners.&nbsp;<span data-preserver-spaces=\"true\">Subscribe to&nbsp;<\/span><\/em>The Design Brief<em><span data-preserver-spaces=\"true\">, LEI&#8217;s newsletter devoted to improving organizations&#8217; innovation capability.<\/span>&nbsp;<a href=\"https:\/\/share.hsforms.com\/1cgM78bPtQOK04fsI-K1weg48bn7?utm_campaign=LPPD&amp;utm_medium=email&amp;_hsmi=116190485&amp;_hsenc=p2ANqtz-_wMAAAPlXrZ8Tp9OM4FqjQ-XMlubWnHmh61FwDVAYv2GVbzszDgDvuVSfp-0bhZR6o95zqHixIBpHl7F2mwDSM1AEqSw&amp;utm_content=116190485&amp;utm_source=hs_email\" target=\"_blank\" rel=\"noopener\">Subscribe now.<\/a><\/em><\/p>\n\n\n\n<p class=\"has-text-align-center\"><iframe loading=\"lazy\" title=\"YouTube video player\" src=\"https:\/\/www.youtube.com\/embed\/IsDKLgaBEqg\" width=\"560\" height=\"315\" frameborder=\"0\" allowfullscreen=\"allowfullscreen\"><\/iframe><\/p>\n\n\n\n<p>It\u2019s still surprising when people want to debate whether an individual\u2019s activity is waste in product development. \u201cYou know,\u201d they say, \u201ca developer\u2019s work is not like manufacturing.\u201d Really? \u201cThat\u2019s so interesting\u201d is my typical response while thinking about missing the forest for the trees.&nbsp;&nbsp;<\/p>\n\n\n\n<p>The fact&nbsp;is&nbsp;that&nbsp;the&nbsp;amount of waste in most product and process development systems is&nbsp;staggering&nbsp;&#8212;&nbsp;and&nbsp;almost&nbsp;none of it has&nbsp;anything&nbsp;to do with the work of individual&nbsp;contributors.&nbsp;Most of the&nbsp;waste in development is the direct&nbsp;result of&nbsp;a&nbsp;poorly designed development system&nbsp;and&nbsp;processes that&nbsp;seem&nbsp;intent on thwarting even the most talented development teams.&nbsp;&nbsp;<\/p>\n\n\n\n<p>I&nbsp;am&nbsp;usually&nbsp;more comfortable talking about value creation in development.&nbsp;It\u2019s more fun,&nbsp;and,&nbsp;after all,&nbsp;creating new value&nbsp;is&nbsp;the point.&nbsp;Unfortunately,&nbsp;most&nbsp;development&nbsp;systems create more&nbsp;frustration&nbsp;than value.&nbsp;They waste&nbsp;people\u2019s valuable time,&nbsp;not to mention&nbsp;copious amounts of organizational resources.&nbsp;Consequently,&nbsp;I think&nbsp;it\u2019s&nbsp;essential&nbsp;that we&nbsp;also&nbsp;discuss&nbsp;opportunities to reduce&nbsp;some of that&nbsp;system-generated&nbsp;waste&nbsp;&#8212;&nbsp;starting with badly designed development processes.&nbsp;Fortunately, the&nbsp;countermeasure to this problem&nbsp;lies in&nbsp;fundamental&nbsp;lean thinking:&nbsp;Make the value-creating steps of product and process development flow.&nbsp;&nbsp;<\/p>\n\n\n\n<div style=\"height:35px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter is-resized\"><img decoding=\"async\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2021\/09\/understand-b4-2.png\" alt=\"\" style=\"width:555px;height:573px\"\/><\/figure><\/div>\n\n\n<div style=\"height:53px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<p>Still,&nbsp;one significant&nbsp;challenge&nbsp;is creating flow&nbsp;when&nbsp;people from&nbsp;across the organization are contributing&nbsp;(or should be)&nbsp;to&nbsp;a new&nbsp;product\u2019s creation.&nbsp;For example,&nbsp;achieving flow&nbsp;might&nbsp;require&nbsp;coordinating&nbsp;the&nbsp;concurrent work&nbsp;of&nbsp;design, engineering, software development, manufacturing, and&nbsp;logistics.&nbsp;And that can&nbsp;seem&nbsp;a&nbsp;daunting&nbsp;task.&nbsp;The key is synchronizing the individual&nbsp;contributing workstreams,&nbsp;and that starts with deeply understanding the&nbsp;actual&nbsp;work.&nbsp;By identifying&nbsp;the&nbsp;interdependencies of&nbsp;critical&nbsp;inputs and outputs&nbsp;across workstreams&nbsp;and understanding the&nbsp;impact of&nbsp;critical&nbsp;decisions,&nbsp;you can&nbsp;keep the&nbsp;process&nbsp;moving&nbsp;steadily&nbsp;forward&nbsp;instead of&nbsp;constantly&nbsp;looping back for&nbsp;expensive&nbsp;rework.&nbsp;<\/p>\n\n\n\n<p>There are two mutually reinforcing approaches to creating flow in development:&nbsp;Building flow into the process at the start and helping your team synchronize work in real&nbsp;time.&nbsp;&nbsp;&nbsp;<\/p>\n\n\n\n<div style=\"height:52px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"aligncenter size-full\"><a href=\"https:\/\/info.lean.org\/synchronizing-workflows\" target=\"_blank\" rel=\"noreferrer noopener\"><img loading=\"lazy\" decoding=\"async\" width=\"600\" height=\"300\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2023\/04\/DB-sync-workflows-pdf.jpg\" alt=\"Synchronizing Workflows\" class=\"wp-image-24898\" srcset=\"https:\/\/www.lean.org\/wp-content\/uploads\/2023\/04\/DB-sync-workflows-pdf.jpg 600w, https:\/\/www.lean.org\/wp-content\/uploads\/2023\/04\/DB-sync-workflows-pdf-300x150.jpg 300w, https:\/\/www.lean.org\/wp-content\/uploads\/2023\/04\/DB-sync-workflows-pdf-150x75.jpg 150w, https:\/\/www.lean.org\/wp-content\/uploads\/2023\/04\/DB-sync-workflows-pdf-375x188.jpg 375w, https:\/\/www.lean.org\/wp-content\/uploads\/2023\/04\/DB-sync-workflows-pdf-190x95.jpg 190w\" sizes=\"(max-width: 600px) 100vw, 600px\" \/><\/a><\/figure><\/div>\n\n\n<div style=\"height:49px\" aria-hidden=\"true\" class=\"wp-block-spacer\"><\/div>\n\n\n\n<p>Building flow into the process ensures the development team makes the most of incomplete but stable information and enables concurrency. To build flow into the process, first design the development tasks and their sequence to maximize the utility of vital inputs and outputs. Then determine milestones and schedule integration events when teams can coordinate and evaluate progress based on agreed-upon quality-of-event criteria. To help this evaluation, be sure to use input requirements as leading indicators of progress. Value stream and decision mapping are often reasonable ways to start your development process re-design.\u00a0<\/p>\n\n\n\n<blockquote class=\"wp-block-quote is-layout-flow wp-block-quote-is-layout-flow\">\n<p>Building flow into the process ensures the development team makes the most of incomplete but stable information and enables concurrency.<\/p>\n<\/blockquote>\n\n\n<div class=\"wp-block-image\">\n<figure class=\"alignright is-resized\"><img decoding=\"async\" src=\"https:\/\/www.lean.org\/wp-content\/uploads\/2021\/09\/screen-shot-2021-06-22-at-12.03.14-pm.png\" alt=\"\" style=\"width:200px;height:219px\"\/><\/figure><\/div>\n\n\n<p>Unfortunately, no process, no matter how well designed, will be sufficient. Organizing and leading your development team to synchronize work in real time during development helps the team respond to inevitable unexpected situations. As Mike Tyson says, \u201ceveryone has a plan until they get punched in the face.\u201d Stuff happens. Things go wrong. Teams need to be able to react and keep making progress in the face of unexpected changes. Effective obeya stand-up meetings and good visual management are very helpful here, and a strong chief engineer leading the program is essential. Depending on the product, you may want to consider organizing cross-functional teams around product sub-systems.&nbsp;<\/p>\n\n\n\n<p>The point is that you need tools and mechanisms that give the team an early heads-up and enable them to absorb inevitable variation and keep moving forward.<\/p>\n\n\n\n<p>In&nbsp;this month\u2019s video,&nbsp;we have&nbsp;excellent examples of both approaches.&nbsp;First,&nbsp;Peter&nbsp;Cooper,&nbsp;platform&nbsp;leader, Medium Wheel Loaders,&nbsp;at Caterpillar,&nbsp;explains how&nbsp;they used&nbsp;value-stream mapping&nbsp;to dramatically&nbsp;reduce&nbsp;waste and create better&nbsp;flow on a set of time-critical development programs.&nbsp;Then Alison Seward,&nbsp;program&nbsp;senior&nbsp;director&nbsp;at GE Appliances, a Haier company,&nbsp;shares her secrets for synching up work across her large&nbsp;development&nbsp;team&nbsp;on a&nbsp;critical new product program.&nbsp;<\/p>\n\n\n\n<p>See the<em>&nbsp;Lean Posts<\/em>&nbsp;and related ebooks detailing other guiding principles:<\/p>\n\n\n\n<ul>\n<li><a href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/putting-people-first\/\" target=\"_blank\" rel=\"noreferrer noopener\">Putting People First<\/a><\/li>\n\n\n\n<li><a target=\"_blank\" href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/developing-products-is-a-team-sport\/\" rel=\"noreferrer noopener\">Developing Products is a Team Sport<\/a><\/li>\n\n\n\n<li><a target=\"_blank\" href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/understanding-before-executing\/\" rel=\"noreferrer noopener\">Understanding Before Executing<\/a><\/li>\n\n\n\n<li><a href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/building-in-learning-and-knowledge-reuse\/\" target=\"_blank\" rel=\"noreferrer noopener\">Building in Learning and Knowledge Reuse<\/a><\/li>\n\n\n\n<li><a target=\"_blank\" href=\"https:\/\/www.lean.org\/the-lean-post\/articles\/designing-the-value-stream\/\" rel=\"noreferrer noopener\">Designing Value Streams<\/a><\/li>\n<\/ul>\n","protected":false},"excerpt":{"rendered":"<p>Two leaders share their secrets of effective value-stream mapping and synchronizing workflows.<\/p>\n","protected":false},"author":1,"featured_media":24733,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_relevanssi_hide_post":"","_relevanssi_hide_content":"","_relevanssi_pin_for_all":"","_relevanssi_pin_keywords":"","_relevanssi_unpin_keywords":"","_relevanssi_related_keywords":"","_relevanssi_related_include_ids":"","_relevanssi_related_exclude_ids":"","_relevanssi_related_no_append":"","_relevanssi_related_not_related":"","_relevanssi_related_posts":"13059,12565,7421,12553,13107,13037","_relevanssi_noindex_reason":"","footnotes":""},"categories":[26],"tags":[],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v22.9 - 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