The biggest improvements come from applying Lean to all parts of the business. The integration of the Lean elements that apply into one comprehensive Lean system produces dramatic results. Here are the key things a business should go through to make the Lean transition:

1. Determine the Value steams: Really look at your business and define the value streams [sometimes called key processes] from the perspective of the customer. Value streams usually have a common set of customers with common problems and are receptive to common solutions. 

2. Pick one of the value streams for a pilot implementation: The best way to discover the impact of the Lean transition is to pick one value stream or portion of the value stream and use it as a pilot implementation. We are all limited with resources and there is generally skepticism about what can be achieved. So, minimize the risk by using a pilot for the first implementation and improve on it prior to full scale implementation. 

3. Organize around the value stream: Take human resources and allocate them to the value stream. Have them take responsibility for the performance of the value stream. People begin to see the needs of the customer and the frustrations of the customer, and they become geared toward meeting the needs of the customer. 

4. Map the processes to understand the operations:  Define the processes and the flows between the processes. Get this down in a flow chart format. Incorporate process times, batch sizes, buffer sizes, inventory, downtime, and changeover time where appropriate. 

5. Make the product flow without waiting:  Flow is a waste buster and has such a dramatic impact on productivity that this must be a key part of the strategy for a lean implementation. The ways to achieve flow include:

   • Layout work in sequence of processes along the value stream with the appropriate use of cells.

   • Reduce the batch quantity to an appropriate size.

   • Develop "Standardized Work" for all processes so the work is performed consistently and the same set of actions are taken to resolve discrepancies.

   • Synchronize cells or processes as appropriate using Pull and Kanban technologies.

   • Implement 5S to achieve a clean and organized work area.

   • As appropriate, implement Quick Changeover, Productive Maintenance, and Quality Management technologies to minimize idle time.

   • As appropriate, implement material handling equipment, process technology, automation, and custom equipment to achieve flow.

6. Examine the scheduling and inventory system: There needs to be an examination of how work is scheduled and what kind of inventory should be maintained to support the customers.  Generally this is an area where there is continued focus and improvement after gaining experience with reduced levels of inventory and batch quantities. 

7. Develop the organization:  Develop people through a focus on team building, training, learning, and empowerment. 

8. Develop problem solving skills:  Implement good problem solving skills with a focus on rapid response and getting the system back on stream.

9. Use Kaizen Events: For localized improvement within the value stream, use Kaizen events. 

10. Realize the objectives:  Keep the objectives in front of everyone. Track the performance to those objectives and don't be afraid to make adjustments in the program to achieve the results. 

11. Learn and reapply:  Take what was learned and move to the next value stream or portion of the value stream. 

We would like to talk with you about your Lean transition needs and discuss how we could make dramatic improvements in your operations. After this discussion we may visit your facility to talk first hand with those involved in making this transition. Please fill out the Lean Transition Information form so that we can contact you and discuss your situation.