Lean Implementation Tips
For Lean implementation to be successful, there must be a balance between both the hardware & software of Lean:
Hardware refers to the tools & techniques (such as kanban, pull, single minute exchange of dies/ SMED/ quick chanageover, poka yoke, one piece flow, etc),
Software refers to the human side of the implementation (such as leadership, communication, motivation etc)
While there is more publicity on the success & power of the tools & techniques of Lean, the secret of success is actually on the human side.
Most lean implementation failures are not due to failure to grasp the tools & techniques but failure in change management. Conversely, most successes in Lean are due to successful change management than their widely published tools & techniques implementation.
Some organizations focus their Lean implementation on tools and techniques and neglect the people aspect of change management , and are left wondering why their Lean implementation is not getting the intended results.
Below are some useful tips on Lean implementation:
1 Prepare and motivate people
Create common understanding of need to change
Communicate the need to change
In the current economic environment, you can even consider using the difficult market condition as a burning platform to rally support from employee for change.
2 Employee involvement
empower decision making and system development down to the “lowest levels”
Train and truly empower people
Share information and manage expectations
3 Identify and empower champions
Remove roadblocks (i.e. people, layout, systems)
Make it both directive yet empowering
4 Positive Atmosphere
Be tolerant of mistakes
Be patient
Be willing to take risks
Create a blame-free culture
5 Establish realistic performance measures, evaluation, and reward systems
Measure results and not number activities/events
Tie improvements, long term, to key macro level performance targets (i.e. inventory turns, quality, delivery, overall cost reductions)
6 Execute pilot projects prior to rolling culture out across the organisation
After early wins in operations, extend across the to other areas & eventually to the entire company (enterprise) or supply chain.
Related pages that you may be interested in:
- Lean
- Value Stream Mapping | VSM
- 5S
- Lean Office
- Total Productive Maintenance | TPM
- Single Minute Exchange of Die | SMED
- Kaizen Event
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