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Chapter 3Tuning the Implementation to the

Needs of the Facility

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There are two times when it is difficult to implement an improvement program◦ when times are bad and when times are good. ◦ When times are bad, profitability is low, resources are tight and

"strategic" activities take a back seat to "survival." ◦ When times are good, profitability is high, resources are focused on

the current source of cash flow.

There are two times when an improvement program is critical◦ when times are bad and when times are good. ◦ When times are bad, profitability is low, a company cannot afford to

continue losing money because of poor quality and performance. ◦ When times are good, profitability is high, the cost of poor quality

and performance is also likely to be high.

When do we start implementing WCM?

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So when do we start? Yesterday! Lean is free! (Just not right away) You must

◦ decide who and how you will support the day-to-day operations while you are trying to improve

◦ determine what “The Goal” is (it is to make money – shhh!)

◦ have dedicated resources◦ have a budget◦ plan improvement activities like you plan daily

work Implementation is an investment - not a cost

Financial Implications

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Start with basic lean training, requiring class topic usage◦ No FYI training◦ Lean 101 type class◦ 1-3 days worth of training/ usage

Start with the simple tools◦ 5S / setup reduction / kanbans / visual controls

Start in an area with a guaranteed win Start with people who are ‘Early adopters’

Once you have these wins – use the savings to support the next implementation

But it cost too much!

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1st – top management 2nd – everyone gets a light introduction at the

same time 3rd – person running the improvement project 4th – people who are involved with the

improvement area – trained by the project person

Ultimately everyone gets some level of training

Who gets the training?

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If you are the average company… Somewhere! Anywhere! Just start!

Do you have scoreboards? Where are you having problems?

Did you create a Value Stream Map? What are your customers complaining

about?

Remember, step 1 is ….. Specify Value

Where do I start?

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Lean Implementation Steps, Plan, Roadmap, Timeline◦ http://kaizenchampions.com/Services.html

Lean.org◦ http://www.lean.org/WhatsLean/GettingStarted.cfm

Gemba Walks webniar◦ http://www.lean.org/events/webinarhome.cfm#walk

Go and See webinar◦ http://

www.lean.org/events/webinarhome.cfm#goandsee

Additional resources