5 Ways to Accelerate Your Lean Roadmap

Many organizations have begun the journey to make their businesses lean. Some have reported early successes while others have struggled or fallen into the rut entitled "flavor of the month." As is usually the case with this kind of organization change, implementation precedes understanding. What follows are missteps, rework, confusion, organizational angst, and the aforementioned "flavor of the month" criticism.

As you continue your Lean Journey here are 5 ways to accelerate your roadmap:

Start With Lean Training for Everyone

The key to implementing any new idea or concept is training. It must be top down training so that everyone is on the same page. The more understanding of what lean manufacturing is all about, why you are implementing it and the expected benefits from it, the more likely you are to get buy-in.

It is very important that everyone in the company become committed to lean culture. In order to make the culture successful, managers and employees need to be aware of waste within the company and be prepared to attack and eliminate it. Making sure that the employees are empowered to do this, not just pushing the job off on someone else, is imperative in the proper function of lean culture.

Ensuring everyone is on the same page will help to avoid conflict. At the same time, it is important to ensure people have the space in which to think about what improvements they think need making.

Use Daily Management to Engage Employee in the Gemba

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.

Lean Daily Management includes three components: (1) alignment of goals and effort; (2) visual data management, daily huddles, and problem-solving; and (3) leader standard work.

Focus on Problem Solving

One of the most common mistakes that companies make when embarking on a Lean transformation is trying to do too much at once. These “boil-the-ocean” initiatives are long, costly and often end up stalling under the weight of their own ambition.

The PDCA cycle (Plan-Do-Check-Act) is a simple and effective framework for lean problem-solving. It guides your employees through four steps: defining the problem and its scope, implementing a solution and testing its results, evaluating the outcome and identifying any gaps, and standardizing the solution and making further adjustments.

Empower Improvement with Kaizen

Kaizen events are a powerful improvement tool because people are empowered to come up with new ideas to help the business. Employees are isolated from their day-to-day responsibilities and allowed to concentrate all their creativity and time on problem-solving and improvement.

The purpose of kaizen is to involve everyone, everywhere, every day in making simple improvements. These small improvements add up overtime and result in an extraordinary and never-ending transformation of processes. Companies which use Kaizens have found they generate energy among those who work in the area being improved, and produce immediate gains in productivity and quality.

Seek Expert Help from Lean Sensei

A Lean coach or sensei provides the necessary guidance, support, and expertise to help organizations navigate their journey successfully. They guide teams in adapting to new ways of working and help them overcome any challenges encountered in the process based on their extensive experience and knowledge of Lean. They help organizations identify inefficiencies in their processes and implement effective solutions.

The challenge with lean is that, despite its attraction to many executives who want to cut costs and increase productivity, a lean process doesn’t happen overnight. There are plenty of obstacles to overcome.

The Benefits of Lean Manufacturing

Lean Manufacturing is a business improvement philosophy that has developed over many years (as well as a collection of lean manufacturing tools), it is a method to better focus your business on the true needs of the customer to help you prevent waste from being built into your system. When properly implemented, lean manufacturing provides many advantages, which include improving flow (material, people, information, and work) and eliminating waste.

I detail many of these benefits below:

Improved Quality – A lot of the activity in a lean environment is geared towards improving quality. As quality issues arise, problem solving techniques are used to root cause the problem. From there, mistake proofing is put in place to strengthen the process and prevent recurrence. As a result, the quality of your product will be improved.

Increased Productivity and Flexibility - In a lean business, employees move parts through the manufacturing process a single piece at a time instead of in batches. The single-piece flow increases productivity and improves the flexibility in production processes. Companies using lean manufacturing processes reduce the amount of time required to manufacture a product, which increases the ability to respond to customer orders.

Total Company Involvement – Lean is meant to involve the whole company. It is not intended to be put into action in only one area. It is a management philosophy which should include every part of your organization. This helps promote the concept that everyone in the company is part of the team.

Better Use of Employees – Lean cuts overproduction by adjusting production to meet customer demand, and it simplifies the product to eliminate extra processing. These activities help your company meet customer demand with fewer employees. Fortunately, this doesn’t require layoffs. As employees are given a chance to increase their skills and abilities, and to fully develop their talent, they will be more productive and effective.

Increased Efficiency – Line balancing will ensure each person in the process is working in the most efficient manner. Standardized work will ensure they are doing it correctly following the same method every time. This leads to repeatability and increased efficiencies.

Optimized Space – Lean principles help reduce excess inventory and eliminate overproducing products. When you are producing no more than what the customer requires and you are shipping all of your products quickly, there will be more physical space on the production floor. This environment is easier to organize and safer to work in. 

Safer Work Environment – Visual management and 5S will help identify when things are out of place. When unnecessary elements are removed from the operation, the workplace becomes much more organized. And an organized work environment is a safe work environment.

Improved Employee Morale – Lean manufacturing methods, when implemented successfully, empower employees to participate in improvements, which can improve worker morale Employee involvement and empowerment will make all members of your company feel like a contributing part of the team. And the reduction of uncertainty in the workplace, as a result of lean, will reduce stress in your team members and lead to improved employee morale.

Lean principles can provide substantial gains for organizations and their employees. By implementing Lean you will become a far more competitive and effective business enabling you to grow your business further.

Tired of the Same Old Routine? Unleash Creative Thinking

It’s extremely easy to get sucked into routines. Are you stuck in the “same old, same old” routine?

1. Do you feel that it’s easier to go along with the way things have always been done, rather than spending time, effort, and energy on an idea that may not even work out?
2. Are you open to implementing new ideas … just not sure how to actually sit down and come up with them?
3. Have you spoken up before in meetings only to have your ideas passed over, shot down, or pushed aside?
4. Are you looking for specific action steps that will help you and your team members spark creative thinking, generate new ideas, and solve pressing problems more quickly?
5. When faced with making a critical work-related decision, do you constantly second-guess yourself and make it almost impossible to stick with your final choice?
6. Do you feel that you and your team members spend an inordinate amount of time spinning your wheels, going in circles, and rehashing the same problems without ever reaching satisfactory solutions?

If you answered YES to any of the above questions, you need creative problem solving and strategic thinking.

Creative thinking is one of today’s most under-utilized business skills … yet it is one of the most powerful. This is often referred to as “thinking outside the box.” It is a way of looking at problems or situations from a fresh perspective that suggests unorthodox solutions (which may look unsettling at first). When you approach problems in a way no one else has, work out imaginative solutions, and think from a strategic perspective, you’ll quickly find yourself way ahead of the game.

Creativity in the workplace is critical to both individual and organizational success. Don’t waste another minute on the “same old” routine and the “same old” results — unleash the creative thinker in you and stand back!

Six Ways to Make Continuous Learning Part of Your Daily Routine

Learning is the key to success—some would even say survival—in today’s organizations. Knowledge should be continuously enriched through both internal and external learning. For this to happen, it is necessary to support and energize organization, people, knowledge, and technology for learning. A learning organization values the role that learning can play in developing organizational effectiveness.

A constant quest for learning provides the means to always be moving forward, to conquer new frontiers and achieve new and exciting goals. Make a point to learn something new every day. Learning new things brings more exciting experiences your way. It allows you to meet other people who can bring further knowledge or learning opportunities. 

Learning needs to become part of your daily routine. You are most likely to succeed if you consistently pursue a learning activity each day. Even five minutes a day can make a tremendous difference.

So how do you make learning continuously part of job? Here are six ways to get started today:

1. Pursue ways to develop and apply specific skills. The most effective way to develop your skills it to make it part of your daily routine. Each day, identify where you can practice new skills and behaviors. Compile a list of people who can support your development. Observe people who are skilled in the areas you are trying to improve.

2. Get the most out of readings and seminars. When you are reading or are attending a seminar, take notes. Search for one insight or application in everything you read. Decide what you will do differently.

3. Involve others in your development efforts. Effective development rarely happens in isolation. Instead, successful learning occurs through a continuous process of feedback and support. Learn from people outside of work and realize that no single person will fill all your needs. Use resources available through professional associations, Web sites, blogs, and so forth.

4. View mistakes as learning opportunities. Mistakes are a problem if you repeat them or don't learn from them. When you make a mistake, ask yourself what you can learn from it.

5. Stay informed about industry practices. Industry practices and standards change so you need to keep up-to-date on developments. Visit other companies and talk with their employees. Attend industry or professional meetings, conferences, seminars, webinars, and other educational events. Join a group of professionals who get together to discuss issues of common interest.

6. Seek out and learn from others who are different from you. Getting input and advice from a wide range of people will provide you with new ideas. Develop a habit of identifying what you can learn from each person you meet. Realize that to keep learning, you need to put yourself into unfamiliar situations. Network with others to learn needed information. 

Everything can contribute to our experience of learning. But as you may realize, learning is incomplete if we don't listen to the voices of those whose background and experiences are different from our own. Part of our learning continuously is opening our minds and hearts to those who propose a different way.

A good manager is acutely aware of what they know and why they know it, as well as what they don't know. They understand the difference between opinions, hunches, and objective facts. A good manager knows that their job is to fill in these gaps in knowledge, not to defend them. Good managers don't ruin their credibility by over-stating their knowledge.

Walt Disney, The Lean Thinker

One of the most successful people that we all know and love is none other than Walt Disney. Walt Disney is the famous voice and creator of Mickey Mouse and the founder of Disneyland. The Father of Mickey Mouse was a Lean Thinker before Lean became well known.

Here are five valuable lessons of competition, the impossible, bias for action, curiosity, and improvement that demonstrate Disney was a Lean Thinker

Competition is Good

“I have been up against tough competition all my life. I wouldn’t know how to get along without it.”

Competition makes you stronger, it makes you better, it keeps you on your toes. Never shrink away from competition; never fail to see the value of competition. Your competitors can provide you with more value than your friends. Learn from the competition, and you will grow.

It’s critical that you embrace competition as well as adversity, Walt Disney said, “All the adversity I’ve had in my life, all my troubles and obstacles have strengthened me… You may not realize it when it happens, but a kick in the teeth may be the best thing in the world for you.”

Do the Impossible

“It’s kind of fun to do the impossible.”

Walt Disney said, “If you can dream it, you can do it.” Life is too short to spend it doing the possible. Learn to pursue the impossible, pursue what others say can’t be done, pursue what has never been done before, pursue your dreams, and turn them into a reality.

You must believe in the beauty of your dreams. Walt said, “When you believe in a thing, believe in it all the way, implicitly and unquestionable.” If you’re going to believe, you might as well believe all the way.

Action Always Trumps Inaction

“The way to get started is to quit talking and begin doing.”

I always say that “well done” is better than “well said,” so quit talking and start doing! Quit planning and start practicing; a plan is good, a good plan is even better, but if that plan doesn't get put into action it’s as useless as a four fingered glove. Learn to get into action, start today, whatever you've been postponing …just do it. If you wait for the perfect time, you’ll never accomplish anything.

Curiosity Brings New Solutions

We keep moving forward, opening new doors, and doing new things, because we’re curious, and curiosity keeps leading us down new paths.

I don’t believe in shortcuts because they take too long.

But if there ever was a shortcut, it’s asking for advice from people who are further down the path to you. Find others who do what you want to do, and seek support from them. Let their past mistakes and failures guide you towards your dream.

If the thought of reaching out scares you, remember that they are a lot like you. At some stage, they've also asked for help on what to do next. Don’t be afraid. Be nice and show them respect. It works.

Get Better Daily

“Whenever I go on a ride, I’m always thinking of what’s wrong with the thing and how it can be improved.”

Every day you should become a little better than you were the day before. If you can become one percent better daily, you can recreate your life every 100 days. Learn to get better daily; look for ways to improve, to be kinder, more intelligent, and more helpful.

Disney’s work continues to inspire us and his world-famous cartoons live on. But some of Disney’s best lessons are about how he approached life with an endless dose of curiosity and determination to entertain and awaken the child within us.

Wouldn't you say these are the mark of a Lean leader? Do you think Walt Disney demonstrated such?