The Stages of Lean (according to Dwight) Beginner implemented one Value Stream Map “future state” and are experiencing the “honeymoon effect” Improvement is daily, and progress is fast. Stalling dealing with the post-honeymoon condition. Lean isn’t as much fun and is no longer new. It still makes sense, but it’s getting a little stale. You… Read more »
Whatever you pay most attention to, most likely, will improve.
Let’s talk about what you can control, each minute, hour, day, week. I am referring to those outcomes you and your team can effect. Perhaps outcomes such as:
COMPETING MARCH 2006
The Stages of Lean and the Art of Kaizen
The Stages of Lean (according to Dwight)
1- Beginner Ã¢â‚¬â€œ implemented one Value Stream Map Ã¢â‚¬Å“future stateÃ¢â‚¬Â and are experiencing the Ã¢â‚¬Å“honeymoon effectÃ¢â‚¬Â Improvement is daily, and progress is fast.
2- Stalling Ã¢â‚¬â€œ dealing with the post-honeymoon condition. Lean isnÃ¢â‚¬â„¢t as much fun and is no longer new. It still makes sense, but itÃ¢â‚¬â„¢s getting a little stale. You get what you measure. What are you measuring?
Changing and Building Culture
Perhaps your companyÃ¢â‚¬â„¢s Ã¢â‚¬Å“Continuous ImprovementÃ¢â‚¬Â process is disappointing. Culture is in the way rather than moving forward.
Examining “Phase II” of your lean transition
Perhaps your company has had some initial success with lean. Possibly, you have successfully addressed the first four Lean Principles (1 Specify Value, 2. Identify the Value Stream(s), 3. Create Flow, 4. Pull to Customer Demand) and are making progress…
Ã¢â‚¬Å“We are good enough.Ã¢â‚¬Â
(or are we?)
What do you think your competition is focusing on right now? Do you believe they are thinking Ã¢â‚¬Å“ABC Inc (your company) has been working on lean for a while now and we will never catch themÃ¢â‚¬Â…
Resilience vs. Brilliance
Okay, so by now maybe you have been implementing your lean program for a few months or years. What have you noticed about the process? Here is what I have experienced with many companies implementing lean…
When I first arrive at a new clientÃ¢â‚¬â„¢s facility I typically find the following:
* Confusion and disorder
* Too much inventory, raw material, WIP and Finished Goods
* No obvious, visible product or process flow
* People and material waiting
* Disconnection between customer requirements and the Ã¢â‚¬Å“supply mechanismÃ¢â‚¬Â
* Ineffective communications
Are you happy with your ERP (Enterprise Resource Planning), MRP (Manufacturing Resource Planning), WMS (Warehouse Management System), or SCMS (Supply Chain Management System)?…
8.5 ways to improve inventory accuracy
1 – 5S Ã¢â‚¬â€œ sort, straighten, shine, standardize and sustain your inventory
Ã¢â‚¬Â¢ Classify and sort inventoried goods according to their turnover (Pareto or ABC analysis).
Ã¢â‚¬Â¢ Get rid of all the obsoletes. Sell them, give them away or throw them away! Why wait?
Ã¢â‚¬Â¢ Create a routine so that poor (dirty and untidiness) conditions are not tolerated.