Production
System
In summary, an example of a lean implementation program would be:-
- Senior management to agree and discuss their lean vision
- Management brainstorm to identify project leader and set
objectives - Communicate plan and vision to the workforce
- Ask for volunteers to form the Lean Implementation team (5-7
works best, all from different departments) - Appoint members of the Lean Manufacturing Implementation
Team - Train the Implementation Team in the various lean tools - make
a point of trying to visit other non competing businesses which
have implemented lean - Select a Pilot Project – 5S is a good place to start
- Run the pilot for 2-3 months - evaluate, review and learn from
your mistakes. This timescale may very according to the
Business involved. - Roll out pilot to other factory areas
- Evaluate results, encourage feedback
- Stabilize the positive results by teaching supervisors how to
train the new standards you've developed with TWI
methodology (Training Within Industry) - Once you are satisfied that you have a habitual program,
consider introducing the next lean tool. Select the one which
will give you the biggest return for your business.
Lean Leadership
The role of the leaders within the organisation is the fundamental
element of sustaining the progress of lean thinking. Key focus areas
for leaders are
- PDCA thinking: Structured Problem Solving (Plan, Do, Check
and Act!).
- 'Go to Gemba' philosophy: Gemba is Japanese for the
shopfloor (where the real value-adding activities are carried
out). So this philosophy implies that there is no better place to
deal with reality than going where reality really is!
- Process confirmation: constantly audit that theory truly
translates into practice.
