It's Best to Start Small
One of the truly great attributes of Lean Manufacturing is that (unlike some other methodologies), with lean you can start small -- and then grow from there. In fact, a Lean implimentation aften begins with a single machine or process -- or even a single metric within that single machine.
After achieving success with the first implimentation of Lean Manufacturing, one can expand the process to other machines. The basic approach to starting a single-machine Lean approoach is as follows:
After achieving success with the first implimentation of Lean Manufacturing, one can expand the process to other machines. The basic approach to starting a single-machine Lean approoach is as follows:
Senior management to agree and discuss their lean vision
Management brainstorm to identify project leader and set objectives
Communicate plan and vision to the workforce
Ask for volunteers to form the Lean Implementation team (5-7 works best, all from different departments)
Appoint members of the Lean Manufacturing Implementation Team
Train the Implementation Team in the various lean tools - make a point of trying to visit other non competing businesses which have implemented lean
Select a Pilot Project to implement – 5S is a good place to start
Run the pilot for 2–3 months - evaluate, review and learn from your mistakes
Roll out pilot to other factory areas
Evaluate results, encourage feedback
Stabilize the positive results by teaching supervisors how to train the new standards you've developed
Once you are satisfied that you have a habitual program, consider introducing the next lean tool. Select the one which will give you the biggest return for your business.
Steps in LEAN
Design a simple manufacturing system Recognize that there is always room for improvement Continuously improve the lean manufacturing system design