7 reason why lean failed you

7 REASONS WHY LEAN FAILED YOUAUTHORED BY: LISA MACHOS

IF LEAN WERE ALL THAT…LEAN implementations provide great benefits:

• Creates Efficiency• Provides Cost Savings

• Promotes Employee Morale• Greater ROI on Internal Operational Projects• Provides Pathways for Innovative Solutions

But… If LEAN were all that, why aren’t there higher adoption rates?

Why Does LEAN have such high failure rates?

‘LEAN’ FAILURE RATES

#1: ‘LEAN’ CONFUSION • Vague Understanding of What LEAN Is & Isn’t

• Mixing Methodologies and Tools

• People Bill Themselves Out as Experts…

#2: ‘LEAN’ EXPECTATIONS • LEAN Expectations Tend to Be Unrealistic

Expectations

• LEAN Implementation Plans Are Just the Plans, Not the Total Implementation

• Reaping the Rewards of a Successful LEAN Implementation Can Take At Least 12-18 Months

#3: FOLLOW THROUGH • Without Consistent Follow Through, Efforts Will

Fail

• LEAN Implementation Requires a Culture Change

• Simple, Fast LEAN Will Never Work

#4: PARTIAL IMPLEMENTATIONS

• Trying LEAN on For Size Will Not Work

• LEAN Works Best By Full Integration

#5: BUY-IN• A LEAN Implementation Must Have Buy-In At

All Levels and With All Participants

• No Persons, Department Should Ever Be Considered Exempt

#6: BAD/ WRONG METRICS• Metrics and Key Performance Indicators (KPIs) Must

Measure the Outputs Correctly to Provide Accurate Information

• Sometimes, Most Times, Metrics and KPIs Require a Observation and Adjustment Period to Ensure Accuracy

• Processes Should Always Endeavor to Capture Metrics Automatically

#7: VARIATION

• Hiring LEAN Will Not Necessarily Get You LEAN

• Amateurs Are Not Experts

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