For every production, there is a waste. Waste is anything that does not add value to the end product. A company should be aimed at working effectively by reducing waste, increasing product quality, and adding value to it. Some of the loopholes of wastes in manufacturing include overproduction, transportation, over-processing, workforce, motion, inventory and others. Lean manufacturing tools is a method used to cut on waste within the system of manufacturing.
Here is a step to step guide on how to implement lean manufacturing tools in business:
To begin with, it is important to change the mentality of the leadership. Contrary to where the orders of solving problems come from the top management in a business, problems should be allowed to choose who solve them best. A team is put in place to oversee the implementation of the tool management process which is set for introduction at this stage.
A map of value and waste is made available and understand by the stakeholders. This should be inclusive of the current, future, and action state maps. With this in check, it is easy for everyone to understand the prospects of the process and what they are dealing with. Value stream mapping is, therefore, important for the implementation of the system.
The process needs continuity in improvement as quoted by Kaizen tool. Getting a facilitator on that line to teach the importance of keeping the consistency should be welcome at all cost. This makes the problem in question get relevant tackling since the training is focused on the particular issue. Here you get tangible results and on time.
The main essence of the management is to improve the value of the products to the clients and the business too. It is advisable that you organize yourself around value streams. You can do this by making certain people responsible for the different tasks accorded to them.
Upon putting Lean journey on the course, it is equally important that you develop an effective communication channel. With this in line, you will be able to get reviews and new ideas on how to implement the process. This makes it easier and better while everyone is making a contribution on the same. In addition, you can make it compulsory for the parties to fully participate.
Once introduced, you should not leave it at that. It should b made an all time event and not just a trial. This stops the tendency of laxity and going back to the normal way of doing things. It is, therefore, important that the leadership stays put and focused on the long term results rather than one event.
There is no change that is accepted 100%. In most cases, resistance has to be there. The management should, therefore, brace for such eventualities that are posed mostly by the middle management as they try to frustrate the efforts. Find it necessary to show the financial implication of Lean before getting the business to believe in the lean production. Try hard to find and showcase edges that show the possibilities of good results and an addition of value.
Change the metrics that add no value to the operations of excellence. Measure a variety of stream metrics to first quality. Understand that for a Company to make it, it has to build on its own journey. Be ready to have an own experience. This helps the company best since they know they best and worst points of strengths and weaknesses.
Hiring and developing lean leaders is equally important. In addition, try as much as possible to make sure that the lineage of the experts flows in the line. You can do this by letting a succession path followed since you are assured that lean tools and techniques will be passed on. This is best done since it involves people with first-hand knowledge of the process. The cycle enables the discipline to stay in place for long enough.
Creating an environment that is friendly for the implementation plays a big role in the realization of the plan. When you are out to make or try out something new, you are bound to make mistakes. This is allowed and should be accommodated for since it is the mistake that you can learn and get better. Creating that environment is, therefore, necessary and leads to positive thinkers risking their ideas.
You can hire an expert to teacher your team. The teacher may not do it all but has the knowledge to what the process entails. They provide advice to the business on how well to go about the lean process. It is important to build the platform of the learning experience by having a teacher do it. At the end of the day, all that matters is data. Make decisions that are aimed at improving the data. This helps the lean tool to be more acceptable.
The tool is aimed at results. This can be done by tracing back on the performance and doing the balancing to see how it has influenced the results. Make reviews and statements for the same. Learning from companies that have previously implemented Lean successfully is advisable. You are able to know to do and what not to. The benchmarking puts you at a better place while making some important decisions.
Select a team that is capable of steering the whole process from planning, resourcing, implementation and following up. This team should be made responsible for the process and held accountable. They should get involved with meeting the external and internal consultants and paving the way forward.
Patience is essential in realizing the desired results. Getting excited or disappointed should be discouraged at all levels. Whether you make it or not, you should do it all over again since the main agenda is to create a culture that is focused on improving and sustaining lean process.
Now you know how to implement lean manufacturing tools in your business. It helps you reduce waste and improve on value for business and customer. With this information, you have a pathway that will greatly assist you. I can highly recommend that you try it out and see for yourself. You can be assured of positive results with no regrets.