lean manufacturing implementation challenges
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The Soft Stuff is Hard
Lean Manufacturing Implementation
Challenges
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Outline
1) Senior leadership engagement2) Engineer and Middle Management
engagement
3) Operator and staff engagement
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1) Senior leadership engagement
Leadership commitment and culture Strategic planning
Goal alignment and Customer focus
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Lean Manufacturing Implementation Challenges
1.1) Leadership commitment and cultureTraditional Culture Lean Culture
Internal Focus Customer Focus
Managers Direct Managers Enable / Teach
Maximise Functional Silos Work in Cross Functional Inter-disciplinary teams
Expert Driven Process Driven
Blame People & Departments Focus on root Causes
Guard Information & Discuss Irregularly Share Information & Discuss Often
Benchmark to Justify not improving just as good Strive for Excellence & drive out waste
Rewards; Individual Rewards; Groups
Supplier is the Enemy Supplier is an Ally
Volume lowers cost Removing waste lowers cost
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Lean Linkages for Sustained Change
STRUCTURE
PS
PROCESS
TOOLS
LEAN
Q
C
FORMAL
AND SYSTEMS
PHILOSOPHY
Lean Manufacturing Implementation Challenges
What does a business
need to do toenhance its chances
of success?
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TAKT TIMETAKT TIMETAKT TIMETAKT TIME PHYSICAL LAYOUT
PITCH CYCLE TIME
5S PULL VALUE STREAM MAPPING
KAIZEN STANDARD WORK
KANBAN VISUAL CONTROLS
WASTE
LEVELING ERROR PROOFING
LEAN TOOLS
Lean Manufacturing Implementation Challenges
Why do leantools inthemselves failto sustain the
lean culture?
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Strategic Improvement
Step Change Improvement
Continuous Improvement
L3
L2
L1
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1-Jan
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Coaching, Daily Problem
Solving & Value Stream
Projects
Business Stategy,
Leadership
& Goal Alignment
Responsible &
Accountable for
performance, problem
solving & work area
Leadership Structure and Purpose
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Stop to fix problems
Go to the gemba (where the truth is
) Empower staff to solve problems
Correct the problem 24 hours
Continuous, small-step improvement Go see, ask why and show respect
Lean Manufacturing Implementation Challenges
Lean Philosophy
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Lean Manufacturing Implementation Challenges
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Lean Manufacturing Implementation Challenges
Preparing the business for Lean Implementation
Short burst of theoryBig chunk of hands-on learning
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Lean Manufacturing Implementation Challenges
Develop a rollout plan
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Lean Manufacturing Implementation Challenges
Sample implementation plan
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Lean Manufacturing Implementation Challenges
1.3) Goal alignment and customer focus
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1.3) Goal alignment and customer focus
To customers (external/internal)
To company and business goals
Meaningful for the teams
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Lean Manufacturing Implementation Challenges
Leadership coach/mentor/teacher
SPIRIT of Lean Mentorship:
If the learner hasnt learned, the teacher hasnt taught
John Shook
If the learner hasnt learned, the teacher hasnt taughtJohn Shook
Why isLeadership
imperative toa successfullean
implementation?
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2) Engineer and Middle ManagementEngagement
Value stream projects
Work on the right problems at the right
time Problem solving
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2.1) Value stream projects
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IN OUTValue Add
Non Value Added
Waste
Waiting
Overproduction
Rejects
MotionProcessing
Inventory
Transport
Staff Utilisation
(Typically 5-15% value add)
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Lean Manufacturing Implementation Challenges
2.2) Work on the right problems at the right time
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2.3) Problem Solving
Lean Manufacturing Implementation Challenges
Whatchallenges doEngineers
face inimplementing
lean?
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3) Operator and staff engagement
Go see, show respect and ask why Mini business
Process confirmation
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Lean Manufacturing Implementation Challenges
Core value respect for people
Teaching Is Our #1 Job3.1) Go see, show respect and ask why
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3.2) Mini business
Lean Manufacturing Implementation Challenges
Set 20-50%
improvement
targets
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Process Confirmation Sheet:
Dedicated time daily
Go, Look, See
Lean Manufacturing Implementation Challenges
3.3) Process confirmation
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Summary
Active leadership commitment Choose the right projects so they are
strategically aligned
Go see, show respect and ask why
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Thank you and Questions
Lean Manufacturing Implementation Challenges