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Consult With Humility

Lean guru? Let’s get real.

Bruce Hamilton
Wed, 08/17/2016 - 14:34
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Body

A friend and colleague remarked to me that “the lean market has become mature,” implying a depth and breadth of lean understanding in industry that I have rarely seen myself.

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Standardized work, for example, almost always looks like time setting to me, an occasional and cursory exercise by industrial engineers to shave seconds from a static work sequence to reduce apparent labor costs. Workers are not even asked to participate. In those instances where a standard work chart is actually posted, it’s rarely up to date; usually it’s from a one-time effort of a long-past kaizen event.

One manager challenged me recently. “Our workers don’t need that; they know their jobs very well,” he claimed—a comment that exposed his misunderstanding of standardized work on several levels. When we then watched the work and compared it to the standardized work chart posted next to the worker, it became apparent pretty quickly that there was an extra person in process, that standard work in process was ignored, and that takt time represented a minimum value.

“The chart is really not for the workers; it’s for you,” I replied. “Do you see why? Can you see what’s happening?”

 …

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Comments

Submitted by paulharbath on Sat, 08/20/2016 - 02:58

Lean support not rewarded

Bruce:

Just had lunch with a past employee of a company that wanted so badly to be "Lean". The company did many things right but the biggest challenge they had was not rewarding employee involvement.

The person I had lunch with created a great production cell with my help. Everytime I went to the area he was explaining to me how he had improved the process since yesterday. He was so excited he could hardly contain himself.

When the company had a reduction in force because of industry demand changes this person was one of the first to go. His enthusiam for improvement was not really considered in the decision. Unfortunately I believe this is more common in industry that not.

Great article on what lean really is and how rarely it is to find a successfull implementation.

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