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 Lean Manufacturing: "Back to Basics"


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To stay current on Lean Manufacturing and Lean Six Sigma knowledge and implementation know-how, subscribe to Bill Gaw's Manufacturing Basics and Best Practices Bulletin and you'll receive his weekly solutions to the reasons why 80% of lean initiatives fail to meet expectations. And as a bonus we'll send you a download copy of our PowerPoint Presentation, "Overcoming Change Initiative Objections and Cultural Roadblocks." (All at no cost of course.).

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5-Reasons Why 80% of Lean Manufacturing Initiatives Fail to Meet Expectations

The Lean Benchmark Report

A while back, the Aberdeen Group, published their “Lean Benchmark Report.” Of close to 300 manufacturers that participate in this study, 90% reported that they are committed to Lean. However, further analysis found that less than 20% of these companies can be considered best-in-class.

Below you will find the 5-reasons why lean initiatives fail to meet expectation and a few lean manufacturing training options that are helping individuals and companies eliminate them. Invest some minutes of your time and check out the reasons and their solutions.

Reason No. 1 is not enough planning.

Solution No. 1:  It's not an "add water and stir" initiative. You can't just decide one day to become lean and think it will happen overnight. You need to determine what constraints are impeding your ability to increase speed, improve quality, and eliminate non-value-added activities. And, finally your tactical plan needs to be developed based on value stream mapping and gap analysis.

Need help... we can guide your management team through Value Stream Mapping, Gap Analysis and lean transformation planning. For details, simply
click here --> Lean Manufacturing Assessment or here---> Lean Manufacturing Consultants

 Lean Manufacturing Simulation GameLean Manufacturing Training: Assessment & Planning

Reason No. 2 is lack of understanding and support for the company's lean initiative.

Solution No. 2:  Unless all employees participating in the lean transformation are convinced that lean manufacturing training is important to its success,  improvements will not meet expectations.

Need help... Bill Gaw designed this "lean manufacturing training" package and a related manufacturing simulation LEGO game to help companies rally company-wide support of their lean initiative...for details simply click
here ---> The Lean Manufacturing Transformation:
 or here---> LEAN Manufacturing Simulation Game: Plus Training Package.

Lean Manufacturing Training: Implementation Lean Manufacturing Training

Reason No. 3 is poor preparation.

Solution No. 3:  Even with the best plan, successful implementation will be evasive if there is not a genuine commitment to employee lean manufacturing training, multi-functional, self-directed work team development and empower-ment.

Need help... For  at-your-site, lean manufacturing training that delivers "make-a-difference," continuous improvements... simply click here ---> Kaizen Event Training  or here ---> Lean Manufacturing Consultants
 Lean Manufacturing Training: KaizenLean Management Training: Kaizen Lean Manufacturing Training: Kaizen

Reason No. 4 would be failure to establish goals and expectations, track daily/weekly progress and carry out corrective actions if and when required.

Solution No. 4:  Determining motivational performance metrics and establishing Key Performance Indicators (KPI) to track performance is paramount to achieving positive, sustainable lean initiative results.

Need help... For a self-directed, Performance Management System
(including the development of the Balanced Scorecard)... simply click
here --->: Manufacturing Performance Measurement and Management Training Package or here---> Lean Manufacturing At-Your-Site Seminars

Lean Manufacturing Training: Perfrormance ManagementLean Manufacturing Training: Performance Management

Reason No 5 is a lack of effective leadership.

Solution No. 5:  Successful, lean manufacturing training, planning , and implementation requires Lean Manufacturing Leaders.

Need help... For a unique, practical and result producing Lean Certifi-
cation Program. with personalized coaching by Bill Gaw,.. simply click
here ---> The Lean Manufacturing Certification with e-Coaching  
or here---> Lean Manufacturing, PowerPoint-Plus Training Presentations

Lean Manufacturing Training: Certificationlean manufacturing simulation excercisesLean Manufacturing Training: Certification

Lean Manufacturing Training that you'll not find in the books
at Amazon.com... neither in the APICS Package 
nor the Harvard Business School Press.  

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