Process Improvement, LLC                                  
  International Business Performance Excellence
  
 
 
   

LEAN PRODUCTION SYSTEM DEPLOYMENT

 

At Process Improvement, LLC we follow and lead companies through Lean Deployments using the 14 Guiding Principles that are at the heart of Toyota's philosophy and success.

Before your organization attempts to implement the Lean Production System, it's time for a management gut check.

Many companies would like to sell you training because they deliver the training and are paid, and the onus is on you to deliver results. At Process Improvement, LLC we do not just offer training. We deliver complete solutions in order to give your people the best chance at success.

Senior leadership should get together and have an open and honest discussion.

Ask yourselves:

  • Are we ready to embrace a change of this magnitude?
    • It is important to know that there is no half-way - no trying out a tool here or there to see how it it works - it won't. Your organization may receive some benefit in the short term, but the benefits will not be sustained and eventually the Lean initiative will be dismissed as another flavor of the month.
    • If you decide to "give it a try," don't. Save your money and time for something that has a chance of achieving ROI
  • Do we have the ability to persevere?
    • To be successful, you must be in this for the long haul. It will require the discipline to consistently apply the principles, systems, methods and tools/techniques over the years in your journey.
    • Don't try to implement too much too quickly. You will overload your resources, they will become frustrated, and will not be able to continue the pace and meet expectations. They will rebel against the systems and you will be forced to either abandon the initiative, or regroup and try again, neither of which is a good outcome.
  • Are we prepared to support this with money, resources, and the time required to educate?
    • The investment will return many times over, but it takes time to build momentum. Altering the way managers manage, creating systems to make problems visible and re-educating the workforce so that your company is truly an improvement culture does not happen overnight. There will be years of investment in your most valuable resource - your people - before you really see the transformation you read about in world-class companies.

Once your organization is committed to the effort you are ready for the most amazing transformation your company will ever see. The results will be sustained and increasing year over year.

  • Guiding Principles established and supported at the highest organizational levels
  • Systems designed to support the principles and provide infrastructure to facilitate employees pursuit of operational excellence
  • Methods that provide the framework for employees to successfully work within the systems
  • Specific, well-defined tools, used within the method framework, for employees to use that help them improve everything they do to work toward the ideal principles
 

The Four Rules to follow in Lean Production Systems

    1. All work should be highly specified in content, sequence, timing, and outcome.
    2. All customer-supplier connections must be direct, and there must be a completely unambiguous way to send requests and receive responses for materials or service. (Customers and suppliers are internal and external)
    3. The pathway for every product and service must be simple and direct.
    4. All improvements must be made using the scientific method under the guidance of a mentor/teacher at the lowest possible level in the organization.