The situation was eerily familiar. A year earlier a chip had cracked off of my tooth as I ate a pizza in Lima, the first stop of a ten week trip to South America. I ate gingerly during the rest of the trip, worried that the tooth would crack further. Luckily I made it back home with no pain and little additional damage. Once there, it took three days to get a dentist appointment. The dentist made an impression of the gap in my tooth and fashioned a temporary crown. “This will have to last for a week or two,” she said. “If it falls out, just stick it back in and be more careful what you eat.” Luckily the temporary crown held, and ten days later a permanent crown arrived from the lab. Two weeks after we arrived home, my tooth was fixed.
We were scheduled to be in Cape Town for only two days. How was Tom going to get a crown replaced in two days? A small committee formed. Someone did a phone search; apparently the Waterfront was a good place to find dentists. A call was made. “You can go right now – the dental office is nearby. Do you want someone to walk you over?” As Tom headed out the door with an escort, I got ready for my presentation. Half way through the talk, I saw Tom return and signal that all was well.
“I lost a part of my tooth, not just the crown,” Tom told me after the talk. “I’m supposed to return at 3:30 this afternoon; I should have a new crown by the end of the day.” The dentist had a mini-lab in his office. Instead of making a temporary crown, he used a camera to take images of the broken tooth and adjacent teeth. The results were combined into a 3D model of the crown to which the dentist made a few adjustments. Then he selected a ceramic blank that matched the color of Tom’s teeth and put it in a milling machine. With the push of a button, instructions to make the crown were loaded into the machine. Cutters whirled and water squirted to keep the ceramic cool. Ten minutes later the crown was ready to cement in place. Ninety minutes after he arrived that afternoon and eight hours after the incident, Tom walked out of the dental office with a new permanent crown. It cost approximately the same amount as my crown had cost a year earlier.
Lean is about Flow EfficiencyThe book This is Lean (Modig and Ahlström, 2013) describes “lean” as a relentless focus on efficiency – but not the kind of efficiency that cuts staff and money, nor the kind of efficiency that strives to keep every resource busy all of the time. In fact, a focus on resource efficiency will almost always destroy overall efficiency, the authors contend, because fully utilized machines (and people) create huge traffic jams, which end up creating a lot of extra work. Instead, Modig and Ahlström demonstrate that lean is about flow efficiency – that is, the efficiency with which a unit of work (a flow unit) moves through the system.
Consider our dental experience. It took two weeks for me get a new crown, but in truth, only an hour and a half of that time was needed to actually fix the tooth; the rest of the time was mostly spent waiting. My flow efficiency was 1.5÷336 (two weeks) = 0.45%. On the other hand, Tom’s tooth was replaced in eight hours – 42 times faster – giving him a flow efficiency of 1.5÷8 = 18.75%.
In my case, the dental system was focused on the efficiency of the lab’s milling machine – no doubt an expensive piece of equipment. But add up all of the extra costs: a cast of the crown for the lab, a temporary crown for me, two separate hour-long sessions with the dentist, plus all of the associated logistics – scheduling, shipping, tracking, etc. In Tom’s case, the dental system was focused on the speed with which it could fix his tooth – which was good for us, because a long wait for a crown was not an option. True, the milling machine in the dentist’s office sits idle much of each day. (The dentist said he has to replace two crowns a day to make it economically feasible.) But when you add up the waste of temporary crowns, the piles of casts waiting for a milling machine, and the significant cost of recovering from a mistake – an idle milling machine makes a lot of sense.
Assume you have a camera and efficiency means keeping the camera busy – always taking a picture of some value-adding action. Where do you aim your camera? In the case of resource efficiency, the camera is aimed at the resource – the milling machine – and keeping it busy is of the utmost importance. In the case of flow efficiency, the camera is on the flow unit – Tom – and work on replacing his crown is what counts. The fundamental mental shift that lean requires is this: flow efficiency trumps resource efficiency almost all of the time.
What is Lean Product Development?During the 1980’s Japanese cars were capturing market share at a rate that alarmed US automakers. In Boston, both MIT and Harvard Business School responded by launching extensive studies of the automotive industry. In 1990 the MIT research effort resulted in the now classic book The Machine that Changed the World: the Story of Lean Production (Womack et al., 1990), which gave us the term “lean.” A year later, Harvard Business School published Product Development Performance. (Clark and Fujimoto, 1991) and the popular book Developing Products in Half the Time (Smith and Reinertsen, 1991) was released. These two 1991 books are foundational references on what came to be called “lean product development,” although the term “lean” would not be associated with product development for another decade.
Clark and Fujimoto documented the fact that US and European volume automotive producers took three times as many engineering hours and 50% more time to develop a car compared to Japanese automakers, yet the Japanese cars had substantially higher quality and cost less to manufacture. Clearly the Japanese product development process produced better cars faster and at lower cost that typical western development practices of the time. Clark and Fujimoto noted that the distinguishing features of Japanese product development paralleled features found in Japanese automotive production. For example, Japanese product development focused on flow efficiency, reducing information inventory, and learning based on early and frequent feedback from downstream processes. By contrast, product development in western countries focused on resource efficiency, completing each phase of development before starting the next, and following the original plan with as little variation as possible.
In 1991 the University of Michigan began its Japan Technology Management Program. Over the next several years, faculty and associate members included Jeffrey Liker, Allen Ward, Durward Sobek, John Shook, and Mike Rother. This group has published numerous books and articles on lean thinking, lean manufacturing, and lean product development, including The Toyota Product Development System (Morgan and Liker, 2006), and Lean Product and Process Development (Ward, 2007). The second book summarizes the essence of lean product development this way:
- Understand that knowledge creation is the essential work of product development.
- Charter a team of responsible experts led by an entrepreneurial system designer.
- Manage product development using the principles of cadence, flow, and pull.
The critical thing to keep in mind is that knowledge creation is the essential work of product development. While lean production practices support learning about and improving the manufacturing process, their goal is to minimize variation in the product. This is not appropriate for product development, where variation is an essential element of the learning cycles that are the foundation of good product engineering. Thus instead of copying lean manufacturing practices, lean product development practices must evolve from a deep understanding of fundamental lean principles adapted to a development environment.
Lean Software Development is a subset of Lean Product DevelopmentIn 1975, computers were large, expensive, and rare. Software for these large machines was developed in the IT departments of large companies and dealt largely with the logistics of running the company – payroll, order processing, inventory management, etc. But as mainframes morphed into minicomputers, personal computers, and microprocessors, it became practical to enhance products and services with software. Then the internet began to invade the world, and it eventually became the delivery mechanism for a large fraction of the software being developed today. As software moved from supporting business process to enabling smart products and becoming the essence services, software engineers moved from IT departments to line organizations where they joined product teams.
Today, most software development is not a stand-alone process, but rather a part of developing products or services. Thus lean software development might be considered a subset of lean product development; certainly the principles that underpin lean product development are the same principles that form the basis of lean software development.
Agile and Lean Software Development: 2000 - 2010It’s hard to believe these days, but in the mid 1990’s, developing software was a slow and painful process found in the IT departments of large corporations. As the role of software expanded and software engineers moved into line organizations, reaction against the old methods grew. In 1999, Kent Beck proposed a radically new approach to software development in the book “Extreme Programming Explained” (Beck, 1999). In 2001 the Agile Manifesto (Beck et al., 2001) gave this new approach a name – “Agile.”
In 2003, the book Lean Software Development (Poppendieck, 2003) merged lean manufacturing principles with agile practices and the latest product development thinking, particularly from the book Managing the Design Factory (Reinertsen, 1997). Lean software development was presented as a set of principles that form a theoretical framework for developing and evolving agile practices:
- Eliminate waste
- Amplify learning
- Decide as late as possible
- Deliver as fast as possible
- Empower the team
- Build quality in
- See the whole
To counter sequential processes and the long integration and defect removal phase, agile software development practices focused on fast feedback cycles in these areas:
- Test-driven development: Start by writing tests (think of them as executable specifications) and then write the code to pass the tests. Put the tests into a test harness for ongoing code verification.
- Continuous integration: Integrate small increments of code changes into the code base frequently – multiple times a day – and run the test harness to verify that the changes have not introduced errors.
- Iterations: Develop working software in iterations of two-to four weeks; review the software at the end of each iteration and make appropriate adjustments.
- Cross-functional teams: Development teams should include customer proxies and testers as well as developers to minimize handovers.
The Difference between Lean and Agile Software DevelopmentWhen it replaced sequential development practices typical at the time, agile software development improved the software development process most of the time – in IT departments as well as product development organizations. However, the expected organizational benefits of agile often failed to materialize because agile focused on optimizing software development, which frequently was not the system constraint. Lean software development differed from agile in that it worked to optimize flow efficiency across the entire value stream “from concept to cash.” (Note the subtitle of the book Implementing Lean Software Development: From Concept to Cash (Poppendieck, 2006)). This end-to-end view was consistent with the work of Taiichi Ohno, who said:
“All we are doing is looking at the time line, from the moment the customer gives us an order to the point when we collect the cash. And we are reducing that time line by removing the non-value-added wastes.” (Ohno, 1988. p ix)Lean software development came to focus on these areas:
- Build the right thing: Understand and deliver real value to real customers.
- Build it fast: Dramatically reduce the lead time from customer need to delivered solution.
- Build the thing right: Guarantee quality and speed with automated testing, integration and deployment.
- Learn through feedback: Evolve the product design based on early and frequent end-to-end feedback.
1. Understand and deliver real value to real customers.A software development team working with a single customer proxy has one view of the customer interest, and often that view is not informed by technical experience or feedback from downstream processes (such as operations). A product team focused on solving real customer problems will continually integrate the knowledge of diverse team members, both upstream and downstream, to make sure the customer perspective is truly understood and effectively addressed. Clark and Fujimoto call this “integrated problem solving” and consider it an essential element of lean product development.
2. Dramatically reduce the lead time from customer need to delivered solution.A focus on flow efficiency is the secret ingredient of lean software development. How long does it take for a team to deploy into production a single small change that solves a customer problem? Typically it can take weeks or months – even when the actual work involved consumes only an hour. Why? Because subtle dependencies among various areas of the code make it probable that a small change will break other areas of the code; therefore it is necessary to deploy large batches of code as a package after extensive (usually manual) testing. In many ways the decade of 2000-2010 was dedicated to finding ways to break dependencies, automate the provisioning and testing processes, and thus allow rapid independent deployment of small batches of code.
3. Guarantee quality and speed with automated testing, integration and deployment.It was exciting to watch the expansion of test-driven development and continuous integration during the decade of 2000-2010. First these two critical practices were applied at the team level – developers wrote unit tests (which were actually technical specifications) and integrated them immediately into their branch of the code. Test-driven development expanded to writing executable product specifications in an incremental manner, which moved testers to the front of the process. This proved more difficult than automated unit testing, and precipitated a shift toward testing modules and their interactions rather than end-to-end testing. Once the product behavior could be tested automatically, code could be integrated into the overall system much more frequently during the development process – preferably daily – so software engineers could get rapid feedback on their work.
Next the operations people got involved and automated the provisioning of environments for development, testing, and deployment. Finally teams (which now included operations) could automate the entire specification, development, test, and deployment processes – creating an automated deployment pipeline. There was initial fear that more rapid deployment would cause more frequent failure, but exactly the opposite happened. Automated testing and frequent deployment of small changes meant that risk was limited. When errors did occur, detection and recovery was much faster and easier, and the team became a lot better at it. Far from increasing risk, it is now known that deploying code frequently in small batches is best way to reduce risk and increase the stability of large complex code bases.
4. Evolve the product design based on early and frequent end-to-end feedback.To cap these remarkable advancements, once product teams could deploy multiple times per day they began to close the loop with customers. Through canary releases, A/B testing, and other techniques, product teams learned from real customers which product ideas worked and how to fine tune their offerings for better business results.
When these four principles guided software development in product organizations, significant business-wide benefits were achieved. However, IT departments found it difficult to adopt the principles because they required changes that lay beyond span of control of most IT organizations.
Lean Software Development: 2010 - 20152010 saw the publication of two significant books about lean software development. David Anderson’s book Kanban (Anderson, 2010) presented a powerful visual method for managing and limiting work-in-process (WIP). Just at the time when two week iterations began to feel slow, Kanban gave teams a way to increase flow efficiency while providing situational awareness across the value stream. Jez Humble and Dave Farley’s book Continuous Delivery (Humble and Farley, 2010) walked readers through the steps necessary to achieve automated testing, integration and deployment, making daily deployment practical for many organizations. A year later, Erik Reis’s book The Lean Startup (Reis, 2011) showed how to use the rapid feedback loop created by continuous delivery to run experiments with real customers and confirm the validity of product ideas before incurring the expense of implementation.
Over the next few years, the ideas in these books became mainstream and the limitations of agile software development (software-only perspective and iteration-based delivery) were gradually expanded to include a wider part of the value stream and a more rapid flow. A grassroots movement called DevOps worked to make automated provision-code-build-test-deployment pipelines practical. Cloud computing arrived, providing easy and automated provisioning of environments. Cloud elements (virtual machines, containers), services (storage, analysis, etc.) and architectures (microservices) made it possible for small services and applications to be easily and rapidly deployed. Improved testing techniques (simulations, contract assertions) have made error-free deployments the norm.
Today (2015), at least in the cloud, automated deployment pipelines are well-supported. Companies delivering software as a service either on the web or via mobile apps are moving to automated pipelines as a matter of survival. Reports from companies that embed software in their products show that here too, automated deployment pipelines are gaining a foothold. (See case study, below.)
However, IT departments still find it difficult to increase flow efficiency, because they have inherited monolithic code bases intertwined with deep dependencies that introduce devious errors and thwart independent deployment of small changes. Often the culprit is the corporate database, once considered essential for running the business, but now under attack as a major source of dependencies. Another set of culprits are outsourced applications, where even small changes are difficult and knowledge of how to make them no longer resides in the company. But perhaps the biggest problem that IT departments face is the distance between their technical people and the company’s customers. Because most IT departments view their colleagues in line businesses as their customers, their technical people lack a line of sight to the real customers of the company; thus insightful trade-offs and innovative solutions struggle to emerge.
The Future of Lean Software DevelopmentAs automated deployment pipelines become common, more companies will adopt the practice, some earlier and some later, depending on their competitive situation. The most successful software companies will continue to focus like a laser on delighting customers, improving the flow of value, and reducing risks. They will develop (and release as open source) an increasingly sophisticated set of tools that make software development easier, faster, and more robust. Thus a decade from now there will be significant improvements in the way software is developed and deployed. The Lean principles of understanding value, increasing flow efficiency, eliminating errors, and learning through feedback will continue to drive the evolution, but the term “lean” will disappear as it becomes “the way things are done.”
— Case Study —
The starting point was to quantify exactly where all the engineers’ time was going. Fully half of the time went to updating existing LaserJet printers or porting code between different branches that supported different versions the product. A quarter of the time went to manual builds and manual testing, yet despite this investment, developers had to wait for days or weeks after they made a change to find out if it worked. Another twenty percent of the time went to planning how to use the five percent of time that was left to do any new work. The reengineered process would have to radically reduce the effort needed to maintain existing firmware, while seriously streamlining the build and test process. The planning process could also use some rethinking.
It’s not unusual to see a technical group use the fact that they inherited a messy legacy code base as an excuse to avoid change. Not in this case. As impossible as it seemed, a new architecture was proposed and implemented that allowed all printers – past, present and even future – to operate off of the same code branch, determining printer-specific capabilities dynamically instead of having them embedded in the firmware. Of course this required a massive change, but the department tackled one monthly goal after another and gradually implemented the new architecture. But changing the architecture would not solve the problem if the build and test process remained slow and cumbersome, so the engineers methodically implemented techniques to streamline that process. In the end, a full regression test – which used to take six weeks – was routinely run overnight. Yes, this involved a large amount of hardware, simulation and emulation, and yes it was expensive. But it paid for itself many times over.
During the recession of 2008 the firmware department was required to return to its previous staffing levels. Despite a 50% headcount reduction, there was a 70% reduction in cost per printer program once the new architecture and automated provisioning system were in place in 2011. At that point there was a single code branch and twenty percent of engineering time was spend maintaining the branch and supporting existing products. Thirty percent of engineering time was spent on the continuous delivery infrastructure, including build and test automation. Wasted planning time was reclaimed by delaying speculative decisions and making choices based on short feedback loops. And there was something to plan for, because over forty percent of the engineering time was available for innovation.
This multi-year transition was neither easy nor cheap, but it absolutely was worth the effort. If you would like more detail, see (Gruver et al, 2013).
A more recent case study of how the software company Paddy Power moved to continuous delivery can be found in (Chen, 2015). In this case study the benefits of continuous delivery are listed: improved customer satisfaction, accelerated time to market, building the right product, improved product quality, reliable releases, and improved productivity and efficiency. There is really no downside to continuous delivery. Of course it is a challenging engineering problem that can require significant architectural modifications to existing code bases as well as sophisticated pipeline automation. But technically, continuous delivery is no more difficult than other problems software engineers struggle with every day. The real stumbling block is the change in organizational structure and mindset required to achieve serious improvements in flow efficiency.
— End Case Study —
CreditThis essay is a preprint of the author’s original manuscript of a chapter to be published in Netland and Powell (eds) (2016) "Routledge Companion to Lean Management"
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