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 Lean Manufacturing: "Back to Basics"


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   Part Shortages
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                          Late Shipments
                                 Customer Complaints
                                       End-Of-Month Scramble

 

 


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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, management development and team training options that are helping companies eliminate them. Invest some minutes of your time and check out the reasons and their solutions.

Reason No 1 is a lack of effective management.

Solution No. 1:  A successful, lean manufacturing transformation requires a lean manufacturing champion.

Need help... For a unique, practical and result producing Lean Manufacturing,
Certification Program. with personalized e-coaching by Bill Gaw,.. simply click here --->  Bill Gaw's Lean Manufacturing Certification Program

Reason No. 2 is not enough planning.

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. And, finally your tactical plan needs to be developed based on value stream mapping and gap analysis.

Need help... we can guide you and your team through Value Stream Mapping, Gap Analysis and lean transformation planning.

For details, click here --> Lean Manufacturing Assessment and Action Plan 

Reason No. 3 is lack of understanding and company-wide commitment for the company's lean initiative.

Solution No. 3:  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 team training" package that features a related manufacturing simulation game to help management rally company-wide support of the lean transformation.

For details simply click here ---> Lean Manufacturing Simulation Game-Plus       

Reason No. 4 is poor preparation.

Solution No. 4:  Even with the best plan, successful implementation will be evasive if there is not a genuine commitment to employee training, work team development and empowerment.

Need help... For at-your-site, "been there, done that" team training
that delivers "make-a-difference," lean manufacturing results... simply click
here ---> Lean Manufacturing, At-Your-Site Seminars

Reason No. 5 would be failure to establish goals and expectations, track daily/weekly progress and carry out corrective actions if and when required.

Solution No. 5:  Determining motivational performance metrics and establishing Key Performance Indicators (KPI) to track performance is paramount to achieving sustainable lean initiative success.

Need help... Bill Gaw's Performance Measurement Tutorial for Managers
includes the development of the Performance/Balanced Scorecard) and Pro- active problem solving... simply click here --->: Manufacturing Performance Measurement and Proactive Problem Solving Tutorial

What Everyone Ought to Know About Training

Believe it... "there is no free lunch!"

If you search the Internet for manufacturing training, you'll come across a ton of stuff... and most of it free.

Now we've had people tell us that there is no need to purchase anything because "you can get so much free stuff on the net."  

Admittedly, there is a ton of free stuff on the net...and if you put it all together you'd probably have over a zillion hours of YouTube videos, and a zillion pages of white papers and case studies.  

So if you had over zillion hours of YouTube videos, and a zillion pages of white papers and case studies would you and your company realize your full growth and earning potentials?  

Let me answer that for you... NOOOOOO! 

Unfortunately, even most "not for free" manufacturing training options fail to meet buyer expectations because they are either:

*  EBooks with little or no effective graphics to optimize learning

*  PowerPoint presentations with no commentary to drive
   home the “how to” of lean tools and technique

*  Videos that deliver information at super speeds but with
   comprehension difficulties

*  Seminars/webinars that present a lot of materials however
   most attendee’s retention rate is less than 25% and relev-
   ant, at-home transformations rarely get started.
 

Bill Gaw's Unique, PowerPoint-Plus Tutorials and Games

Our "PowerPoint-Plus" tutorials includes powerful, PowerPoint charts and graphics, "plus" annotated note pages with “how to make-it-happen” commentary and "lessons learned" by Bill Gaw a "been there, done that" lean manufacturing champion.

One of the  keys to success is having a great coach. Whether you're "in the trenches" or working your way up the corporate ladder. the experience of someone who's "been there, done that" can be invaluable. Throughout his training materials, Bill Gaw provides expert knowledge, support, empathy, respect and, most important, the wisdom of experience. and, he's always just an email away.

A PowerPoint-Plus Tutorial's Biggest Advantage

Customers study their PowerPoint-Plus tutorial, print sections and highlight passages that are important to understanding and master. The resultant guidelines are used for team empowerment, motivation and the successful implementation of their lean transformation. eBooks, basic PowerPoint presentations, videos, and seminars/webinars just don’t provide the same capability nor performance results.

Another plus is that every tutorial includes a "Train-the-Trainer" manual should your objective be to use the tutorial material for team training,
 

 Bill Gaw's Free Manufacturing Basics
and Best Practices  (MBBP) Bulletin
(15,000 plus subscribers)

Manufacturing Training at no cost to subscribers

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, "An Introduction to Kaizen Based Lean Manufacturing" (All at no cost of course.).

 Simply fill in your first name and email address and click on the bar below:

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Here's what one subscriber wrote about Bill's MBBP:

"Great manufacturing management articles. Thanks for the insights. I often share portions of your articles with my staff and they too enjoy them and fine aspects where they can integrate points into their individual areas of responsibilities. Thanks again." 

                                   Kerry B. Stephenson. KALCO Lighting, LLC  

Lean Manufacturing Knowledge and skills that you'll
not find in the books at Amazon.com... neither in the
APICS Library nor the Harvard Business School Press.  

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