'There is nothing so useless as doing efficiently
that which should not be done at all'.
Process Experts Improve Lean Success
by Martin Nazareth, President
of OpEx Solutions
In our continued quest for a solution to the problem of unsuccessful and unsustainable implementation
of Lean and other operational excellence systems, we conducted a panel discussion on leadership traits for successful transformation
at the IIE Annual Conference. Panelists and audience from companies like John Deere, DuPont, MD Anderson, Boeing, FedEx, UPS,
Edwards Lifesciences, Premier, Office Depot, OpEx Solutions, and others actively participated in the discussion.
ten new gaps (not covered in our previous articles) include:
- Starting to see resistance to the term “Lean”
largely due to failed application of tools
- Lean experts have led companies by spending a dollar to save a dime
waste comes naturally to Asians and it does not to the Americans
- Leadership is not engaged and has not learned the
tools — does not lead by example
- Need to drive past integration to make continuous improvement part of companies’
DNA — normal way of doing business
- Burning platform in healthcare (current/future changes) — too reactive
through acquisitions impedes stability and continuous improvement
- Lean is applied to production operations and seldom
to product development or service
- Only 20% of organizations lead their transformation using degreed industrial engineers
- Lean tools are basic IE tools — the more we break down IE tools, the less effective they become
good news is that we see a new trend. Process and technical experts are starting to take the lead with the true intent of
making operations successful rather than taking pride in implementing tools. They are bridging the original gap, in the American
companies, of not involving the doers. With the economic challenges, the unions are also cooperating better than they ever
The recommendations that came out of the session include:
- Proper transformation solves
key problems rather than tool implementation
- Process and technical experts are best suited to solve the problems
Toyota Leads Kaizen CenTex
Consortium Learning Event
Toyota Motor Manufacturing, Texas, Inc., hosted a CenTex OpEx Consortium Learning Session
on October 10, 2012 at its plant in San Antonio, Texas. Twenty nine people from eleven different organizations participated
in the session.
Famous for it's Toyota
Production System (TPS), Toyota is the name everyone thinks about when when kaizen (continuous improvement workshops) is
mentioned. Lunch was followed by a presentation of how Toyota does kaizen and how it should be used for most effective results.
After the presentation, a riding tour of the plant was taken and then it was back to the meeting room where a quick benchmark
was done and individual questions were answered by Toyota.
This is one in a series of Learning Sessions hosted by Toyota for the CenTex OpEx Consortium. The
next session (available only to members of the Consortium) will be on March 7, 2013 and will focus on Standard Work.
OpEx Solutions is an organization to help identify strategic areas
for improvement and provide effective high value low cost solutions, training, and project management to drive significant
productivity improvement through the use of operational excellence tools and systems in most manufacturing and service industries.
With a variety of offerings to choose from, we're
confident of working with your organization to find and define your own way through:
If you have any questions or comments, please feel free to contact us.
Find out more About Us, then look at our Stategy to make your possibilities a reality.
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