Building a Lean enterprise

How to successfully implement Lean

Our experts in the Strategic Manufacturing Unit (SMU) can help you get started with your Lean implementation. The initial assessment phase consists of the following steps:

1. The client completes the initial contact information sheet.

2. The client contacts the SMU to schedule an on-site assessment. This typically includes a walk-through of the plant, and can last anywhere from three to eight hours.

3. A member of the SMU will conduct an on-site assessment. This generally consists of a meeting with plant management, a walk-through of the plant with the plant/production manager, and a closing meeting.

4. The SMU prepares a Report of Recommendations, and recommended next steps in the Lean process. This is submitted to the client for review.

5. The client receives the SMU Report of Recommendations and suggested next steps.

6. The client determines whether or not to move forward with Lean implementation. The client can choose to:

• hire SMU professionals to aid them through the Lean implementation
• hire external consultants or employees to execute the Lean implementation

Getting Lean training

Getting Lean training for your business can:

• provide the tools you need to understand how Lean production can be driven by real customer needs, rather than by traditional forecasting

• help to identify waste and how waste can be eliminated

• show how managers and workers can work together to optimize processes and practices

Managing in a Lean organization

To overcome resistance and fear, management should make clear to employees that Lean is a strategy for growth; it is not simply a cost-cutting exercise.

Successful Lean implementations lead to higher revenue growth as compared to the competition and more investment in new technology and in Research and Development. This in turn leads an organization to further expand into new markets and stimulate even more business growth and other benefits.

Lean implementations that strictly look upon Lean as a cost-cutting exercise are typically not sustainable.

Change management and good communication is critical during a Lean transformation. Employees fear losing their jobs, and become resistant to change. To successfully manage a Lean implementation, management should:

• announce that jobs may change, but that growth is the goal

• announce that people won't lose their jobs through continuous improvement

• ensure Lean advocates work to motivate participants in the implementation of Lean

• ensure you have energetic and optimistic Lean advocates promoting Lean within the organization; Lean advocates need to be open-minded to opportunities, possibilities, and ideas

• involve people from all areas and levels of the organization to eliminate waste and identify true value-added activities

• reduce fear by educating employees so that they understand the benefits and activities of Lean implementation

• use Lean to get the plant back into competitive shape

Setting up a Lean timeline

What is a Lean timeline, how do you set it up, and what items should be included?

Your Lean implementation timeline should help you to organize the various research, activities, reorganization tasks, workforces, and schedules. The Lean Enterprise Assessment Program (LEAP) encompasses the various stages of the Lean implementation process.

Using LEAP to implement Lean

Lean implementation includes several key phases that need to be approached in a methodical and logical manner. By following the methodology shown in the "LEAP Roadmap to Success", you can be assured that you are covering all the most important steps, and that your Lean implementation is more likely to succeed.

Date Updated: Jan 15, 2008
RDP-534