Organizations looking to implement the Lean methodology or some of its tools obviously pursue objectives related to improving the performance of their processes. In this search, many organizations have failed to achieve significant results. For this reason, it is very important to consider that Lean Manufacturing is a philosophy that requires organizational commitment and that requires a cultural adaptation. Through Lean Manufacturing’s implementation process expertise, experts have considered that there are three key principles for proper implementation of Lean activities:
- Lean Manufacturing is a strategic project: In such a way that it must be included in the organizational strategic plan and related to the company’s competitive priorities.
- The organizational structure must be adapted to the Lean methodology: in such a way that there are more concurrent processes and less “communication on the wall”, that is, that functional structures must migrate to collaborative structures.
- Lean Manufacturing is a commitment of all: Implementation of the strategy will be gradual but must be integrated at all levels of the organization. The biggest change in the company must be of a culture type, improvement must become a habit of all.
Phases of a Lean Manufacturing project
PHASE 0: TRADITIONAL – Preparation (1-3 months)
- Diagnosis of the company’s current situation
- Plan Hoshin Kanri
- Promotion
- Equipment
- Lean Management
- Preparation 5’s
PHASE 1: APPLICATION – Pilot Areas (4-6 months)
- 5’s application
- Pilot team training
- Current VMS, current and proposed layout
- Productivity Limiting Analysis (MUDAS, MURIS, MURAS) Work Plan
PHASE 2: VALUE CHAINS – Value Chain Management (1-2 years)
- Organization chart approach
- Phase 1 implementation in all areas
- Lean Accounting
- Lean Logistics
PHASE 3: LEAN ORGANIZATIONS – Slender Thought (Permanent Habit)
- Discipline
- Commitment
- Knowledge
- Culture
- Innovation
- Motivation
Basically the traditional stage on the Lean trail consists in diagnosing the current situation of the organization, to design an appropriate strategic plan and form an optimal team of work. The first stage of application confronts the organization with the challenges involved in a new work philosophy, in such a way that a first experience is acquired in which the errors and the ability of the organization to obtain results from the techniques used are acquired. The value chains stage focuses on the structure of the organization, so that a process-based, non-departmentally-based concurrent work model is implemented, phase 1 application is extended to other areas, Lean logistics and accounting are initiated, so that delivery processes are optimized and performance indicators are established for decision-making based on results and vital information.
The final stage is intended to achieve a Lean organization, making there a Lean thought, based on commitment, discipline and knowledge management. A Lean organization should reflect in all its areas and processes the greatest possible value, and in all its members, the idea that such an organization is the best place to work.
Key principles and implementation phases of Lean Manufacturing
