After a few weeks as a Supply Chain Manager for an enterprise that had recently been divested and sold to a large global conglomerate, I approached the plant manager about looking into applying some Lean Methodologies to what was happening in the plant. His answer was one of the most surprising responses that I received in my career - the factory had ‘already done’ Lean. One of the major components of Lean Methodology is the concept of “Continuous Improvement” and stating that Lean was “done” makes no sense to someone who understands Lean.
Lean Improvements are much like the layers of an onion. The outside layers of the onion are easy to see and often easy to correct. These provide quick improvements. Once you get through the first layers of the onion, things get more difficult. Changes require more effort and sometimes discomfort. Many managers will shy away or decide that they’ve done enough.
What is lean? Lean methodology is a business management approach that aims to maximize customer value while minimizing waste. It is based on the principles of the Toyota Production System, which was developed by Toyota Motor Corporation to increase efficiency and eliminate waste in their manufacturing processes.
Waste, as defined by Lean includes overproduction, unnecessary inventory, unnecessary motion, defects, excess processing, unnecessary waiting, and overprocessing. By identifying and eliminating these types of waste, a company can streamline its processes and improve efficiency, resulting in cost savings and increased customer satisfaction.
One of the key tools used in lean methodology is the "value stream map," which is a visual representation of the flow of materials and information through a process. This helps to identify areas where waste is occurring and to develop strategies for eliminating it.
Lean methodology can be applied to any type of business, including manufacturing, healthcare, and service industries. It requires a culture of continuous improvement and a focus on the needs of the customer. When implemented effectively, lean methodology can lead to significant improvements in efficiency, quality, and customer satisfaction.
Lean doesn’t have to be hard. With cursory training and basic guidance, you can begin to implement Lean in your enterprise and ultimately start putting dollars to the bottom line. Reach out and ask how we can help!