Lean Manufacturing e-Bulletin
To stay current on Lean Manufacturing knowledge and
subscribe to Bill Gaw's free Lean Manufacturing e-Bulletin and you'll receive his
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 his Executive Summary: "10-Basics of
Manufacturing" and our e-Book,
"Thinking-Outside-the-Box.". (All at no cost of course.).
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
Fail to Meet Expectations
is lack of effective lean manufacturing
Solution No. 1:
Successful lean transformations require leadership
that has mastered the basics of lean manufacturing and the skills to
train and empower self-directed work-teams.
Certified Lean Manufacturing Champion (CLMC)
Management Development Program.
of understanding, commitment, and participation for the company's
Solution No. 2:
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
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. This product is the only game that demonstrates
the differences between MRP (PUSH) and LEAN (PULL) systems and vividly shows the
huge non-value-added costs of the MRP (PUSH) system.
Reason No. 3
is not enough planning.
Solution No. 3:
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
The Lean Manufacturing
e-Library for guiding your manufacturing team to a successful implementation
.PPT and .PDF e-Library
is lack of "been there, done that" training.
Solution No. 4:
with the best plan, successful
implementation will be evasive if
there's not a genuine commitment to
employee lean manufacturing
training, team development
implementation skills guaranteed to deliver a successful Lean
Manufacturing Transformation, Team Training Program
would be failure to
develop Continuous Improve-ment Champions that establish goals and
daily/weekly progress and
carry out corrective actions
if and when required.
Solution No. 5:
performance metrics and
establishing Key Performance
Indicators (KPI) to track
performance is paramount to
Financial reports only track the war... it takes Continuous
Improvement Champions to define and win the battles along the way. .
Continuous Improvement Champion Program