Quickest way to map a process is to walk it : The client was part of a large multinational company and struggling to deliver the required engineering services to other parts of the parent company. At the start of our work delivery of over 40% of engineering projects was late to schedule, threatening the overall project schedule. This situation meant the management team was coming under a lot of internal pressure and losing the respect…
Background In the book ‘Switch: How to Change Things When Change Is Hard’ by Chip and Dan Heath they argue that all change needs to do two things. One there must be a rational reason for change to happen and second there must be an emotional reason for change to happen. And when the two come together then change can and will happen. Yet in leading many Lean transformations the critical factor that senior management…
Learning and Unlearning in Lean thinking One of the challenges of implementing Lean thinking is that much of Lean goes against what people have often been traditionally taught. Lean thinking also goes against how people have been rewarded for their performance. Think of Pavlov’s dogs, they were taught (very simplified) to associate the ringing of a bell with being fed and would salivate when they heard a bell ring. People are similar but more complicated….
Talking about Continuous Improvement One of the wonderful parts of my job is I have been able to work with a number of very good leaders. The challenge for many CEO is how to engage in Lean when there is so much else demanding their attention. Situation This Client had grown quickly and was now started on their Lean Journey. The shape of the journey had not taken shape, staffs were highly engaged but to…
Closing the perfection gap in service Excellence happens when you identify a gap and can close that gap. Let me give you an example of how a company I did some work with reject orthodoxy to do that. The company sold and serviced motorized equipment. As an independent distributor they had a little more autonomy in the way they could work with customers than the traditional big company distributor. The big company wanted to be…
Choose your bottleneck One of the primary rules of the Theory of Constraints (TOC) or Bottleneck theory as it is often called is that every process and hence every business has a bottleneck. Now that bottleneck can be inside the business or it can be outside. Most people are familiar with the idea of an internal bottleneck; company capacity being limited by the capacity of a piece of equipment or the number of bays in…
One of the written/unwritten tenants of Lean is to “Borrow with Pride” and its sister to “Share with Pride”. Cyclingnews.com every now and again will do a photo essay on a bike factory they have visited. This time they were visiting Full Speed Ahead Bicycle Components | FSA www.fullspeedahead.com . Looking through the pictures I saw a couple of examples of good Lean practices and a new idea I had not seen before. The new…
Lean was introduced into businesses some time ago. The basic definition, that it mainly curbs on the waste, however, has remained unchanged since its introduction. Though it has now been acknowledged worldwide as a sound process to reduce waste, other effects it has on the business as a whole are often undermined or simply overlooked. One of the key developments after Lean is implemented is the incorporation of single-piece flow, whereby batch or lot production…
The concept of lean manufacturing was developed only after the recognition of wastes in the manufacturing process that cause a loss of money and material resources. Unfortunately, there are no set of instructions, and every practitioner has to make the process more efficient and less wasteful with his own creativity. What is almost same everywhere is kind of wastes that are present, which are also discussed below- Lean finds its origin in the Japanese manufacturing…
For Entrepreneurs who are only just starting up, they are not only the idea generators, but also managers who have to take key decisions for improving the efficiency of their business process. Lean methodology goes a long way in making these decisions easier. It is the age of the startup. Entrepreneurs are everywhere, as businesses big and small are birthing around the clock. Not all of these businesses survive. Most businesses either fail to live…