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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.
 


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

Reason No. 1 is lack of understanding, commitment, and participation for the company's lean transformation.

Lean Manufacturing Training

Solution No. 1:  Unless all employees participating in the lean transformation are convinced that the lean manufacturing initiatives are important to individual and company success, lean transformation will not meet expectations.

DIY help... Click here--->Lean Manufacturing Simulation Game to help your company's training program communicate the need for lean transformation and rally company-wide support and participation of the program.


Reason No. 2 is not enough planning.

Lean Manufacturing Training: Assessment & PlanningLean Manufacturing Simulation Game

Solution No. 2:  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.

DIY help...  Three tutorials for guiding your manufacturing team to a successful implementation plan,  click here--->Lean Manufacturing Planning, Value Stream Mapping, and Resource Planning.


Reason No. 3 is lack of "been there, done that" training.

Lean Management Training: Kaizen Kaizen Stock PhotoLean Manufacturing Training:  Kaizen

Solution No. 3:  Even with the best plan, successful implementation will be evasive if there's not a genuine commitment to employee lean manufacturing training, team development and empowerment.

DIY Help... Lean manufacturing knowledge and implementation skills guaranteed to deliver a successful Lean Transformation. Click here---> Lean Manufacturing Team Training Program

Supply Chain Management knowledge and implementation skills guaranteed to deliver a successful Point-of-Use supply. Click here---> Supply Chain Management Training


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 transformation results.

DIY help... Financial reports only track the war... it takes performance management to define and win the battles along the way. Performance/ Balanced Scorecards provide the way. Click here---> Manufacturing Performance Management Training


Reason No 5 is lack of effective lean manufacturing leadership.

Lean Manufacturing Training: Certification

Solution No. 5:   A lean transformation requires professional leadership  with a primary goal of training and empowering self-directed work-teams.

DIY help... Click here---> Lean Manufacturing Certification Program.


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