lean manufacturing implementation challenges

7/27/2019 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

Lean Manufacturing Implementation Challenges


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1) Senior leadership engagement

Leadership commitment and culture Strategic planning

Goal alignment and Customer focus



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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


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


Why do leantools inthemselves failto sustain the

lean culture?


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Strategic Improvement

Step Change Improvement

Continuous Improvement

L3

L2

L1

0

10

20

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50

1-Jan

1-Feb

1-Mar

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1-May

1-Jun

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1-Aug

1-Sep

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1-Nov

1-Dec

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 Philosophy


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Preparing the business for Lean Implementation

Short burst of theoryBig chunk of hands-on learning


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Develop a rollout plan


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Sample implementation plan


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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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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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2.2) Work on the right problems at the right time


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2.3) Problem Solving


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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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


Set 20-50%

improvement

targets


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Process Confirmation Sheet:

Dedicated time daily

Go, Look, See


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

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