The Role of Lean Daily Management in Sustaining a Lean Culture

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Many companies that experience great success with Lean hold kaizen workshops to rapidly implement Lean tools. It’s no secret, however, that many of these companies find that the improved system quickly reverts back to its non-Lean state. The problem is that Lean is a people-dependent system.  All the Lean tools, such as posting standard work, require people to use them daily and if they do not understand them, or care about them, the tools will quickly decay. We need to develop people so that they want to use the tools for daily improvement. There is no single tool that develops people, but there is a methodology that can aid in their development often referred to as Lean Daily Management.

Lean Daily Management is a systematic strategy for building Lean habits and managing continuous improvement and daily operations in the workplace. It involves multiple aspects, such as Leader Standard Work and Lean management routines, visual management boards, daily accountability, and problem-solving where the work happens (Gemba).

Lean organizations make use of Lean Daily Management systems, a structured process to focus employee’s actions to continuously improve their day-to-day work. Lean Daily Management empowers employees to identify potential process concerns, recommend potential solutions, and learn by implementing process changes. Lean Daily Management, if done right, can be a critical tool in any organization’s toolbox to engage frontline staff in problem-solving and to deliver customer value.

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Read more from my article published by Quality Magazine: The Role of Lean Daily Management in Sustaining a Lean Culture

With Lean day-to-day management, employees are empowered as they play an active role in detecting and resolving problems.

Tips for Running Effective Daily Management Meeting

Lean organizations make use of Daily Management systems, a structured process to focus employee’s actions to continuously improve their day-to-day work. Daily Management empowers employees to identify potential process concerns, recommend potential solutions, and learn by implementing process changes. Daily Management, if done right, can be a critical tool in any organization’s toolbox to engage frontline staff in problem-solving and to deliver customer value.

Here are my tips for running an effective daily management meeting.

Segregate Meetings With Management Levels (Tier 1, Tier 2, Tier 3)

It is important to segregate meetings with management levels (tier 1, tier 2, tier 3) because it allows for more focused and efficient communication within each level. Each level of management has different responsibilities, expertise, and decision-making authority, and holding separate meetings allows each level to discuss issues and make decisions that are most relevant to their respective roles.

Tier 1 meetings typically involve front-line supervisors and focus on day-to-day operations and problem-solving. Tier 2 meetings involve middle managers and focus on longer-term planning and strategy. Tier 3 meetings involve senior executives and focus on high-level strategic planning and decision-making.

Meet In Person Near the Gemba

These meetings should be conducted on the shopfloor in a safe area where communication is easily heard. While there are many digital solutions these days I prefer the manual versions.

Set a Time Limit

Time is of the essence in a factory, and employees often have limited time to spend in meetings. Therefore, it’s essential to keep these meetings short and focused. Aim for a maximum of 15 to 30 minutes and prioritize the most critical issues that need to be discussed.

Start with Positive News

Starting the meeting on a positive note can set the tone for the rest of the meeting. Begin by sharing any good news, such as meeting production targets, or recognizing team members for their hard work.

Safety is Next Concern

Safety is a top priority in any factory, and daily huddles provide an opportunity to discuss any safety concerns or near-misses that have occurred. Discussing safety measures can help prevent future incidents and ensure the safety of all employees.

Don’t Solve Problems in Real Time

An effective daily huddle makes it so someone can acknowledge that they can help a fellow team member without turning it into a troubleshooting session.

Capture Action Items

When action items are assigned, they should be owned by the person responsible for them. This should include specific tasks that need to be completed before the next meeting or when it will be completed.