How can you align your lean manufacturing program with company goals?

1 Assess your current state

Before you can implement any lean improvements, you need to understand your current situation and identify your gaps and opportunities. You can use tools such as value stream mapping, 5S, and SWOT analysis to map out your processes, resources, and performance indicators. This will help you to see where you are wasting time, money, or materials, and where you can add more value to your customers.

2 Define your desired state

Once you have a clear picture of your current state, you can set your goals and objectives for your lean manufacturing program. You should align your goals with your company vision, mission, and values, as well as with the needs and expectations of your customers. You should also make your goals SMART: specific, measurable, achievable, relevant, and time-bound. This will help you to track your progress and evaluate your outcomes.

3 Plan your actions

After you have defined your desired state, you can plan your actions to achieve it. You can use tools such as PDCA (plan-do-check-act) or DMAIC (define-measure-analyze-improve-control) to structure your improvement projects and follow a systematic approach. You should also involve your team members and stakeholders in the planning process, and communicate your vision and expectations clearly.

4 Execute your actions

The next step is to execute your actions and implement your lean improvements. You should follow the standard operating procedures (SOPs) and work instructions that you have developed or revised, and use tools such as kanban, kaizen, and poka-yoke to optimize your workflow, reduce waste, and prevent errors. You should also train and empower your staff to apply lean principles and practices, and provide them with feedback and recognition.

5 Monitor and measure your results

As you execute your actions, you should monitor and measure your results and compare them with your goals and baselines. You should use tools such as dashboards, scorecards, and KPIs (key performance indicators) to track your metrics and indicators, and use tools such as control charts, histograms, and pareto charts to analyze your data and identify trends and patterns. You should also collect feedback from your customers and stakeholders to assess their satisfaction and loyalty.

6 Review and improve your processes

The final step is to review and improve your processes based on your results and feedback. You should use tools such as root cause analysis, fishbone diagrams, and 5 whys to identify the causes of any problems or deviations, and use tools such as brainstorming, affinity diagrams, and A3 reports to generate and evaluate solutions. You should also celebrate your successes and share your best practices and lessons learned.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?