Lean: Is It All or Nothing?

Lean: Is It All or Nothing? – Manufacturing Executive Community- Question posted originally on: http://www.manufacturing-executive.com/message/2637

Enrique’s answer:

A company can often obtain small gains by utilizing the Lean tools.  For instance, using 5S to organize the shop floor results in immediate gains in productivity and accident prevention.  However, sustainability of the improvements depends on the last two steps “standardize” and “sustain”. This is where most organizations fail and where the development of a Lean culture is necessary.

The development of a Lean culture takes time, as Matt mentioned above.  As people start seeing the benefits of Lean, they will start getting involved in improvement efforts.  Lean is all about incremental improvements that add up over time.  If large gains are obtained initially, that is icing on the cake.

The emphasis should be on Continuous Improvement and waste elimination, not on cost savings (these will come soon enough).  Training, education and empowerment at all levels are also essential to developing a culture where waste elimination is an integral part of the organization.