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7 factors for a successful Lean transformation

1. Clear business case
2. Leadership endorsement
3. Clear roles, responsibilities and focus
4. Dedicated internal resources
5. Structured method
6. Simple metrics to track performance
7. Frequent performance reviews

Source: Lean Enterprise Institute

Links

Realizing the Potential of Lean – presentation from Dan Jones.

Insights

• The key objective is wide workforce involvement in problem solving and continuous improvement.
• Lean provides a whole system approach including both the people and process elements.
• Use people experienced with Lean to develop the internal expertise of your people.
• Process improvement is a team activity. Involve all levels in the improvement effort but recognise that those working in the process are the experts.
• Key to sustaining the gains is the buy in from operators and support from management.
• Respect for individuals is key.  This is an opportunity for the people that work in the process to implement their ideas for improvement.
• Successful change will build momentum for people to get involved.
• The culture change needs to be driven by leadership and supported with resources and training.
• Implement Lean tools first, starting with the basics of 5S, visual workplace and standardised work. This activity engages the workforce and forms the foundations of stability and control.
• Use Value Stream Mapping to plan the implementation.
• Start with key but smaller areas first to demonstrate success, then expand.
• Intensive improvement workshops (kaizen events) and a good way to generate team buy in and achieve results in the short term.
• Steal shamelessly and learn from you own and other’s mistakes.
• Progress will take longer than you expect – persevere.
• Lean is a journey not a destination. There is always further opportunity for improvement.