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What is the best way to scale lean practices across your organization?

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Lean manufacturing is a philosophy and a set of tools that aim to eliminate waste, improve quality, and increase customer value in any production process. But how do you scale lean practices across your organization, especially if you have multiple sites, teams, and products? In this article, we will explore some of the best ways to spread lean culture, align your goals, and standardize your methods.

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Tim N.

National Head of Planning - Operations & Manufacturing Partnerships @Greenstock

1 Assess your current state

Before you can scale lean practices, you need to know where you are and where you want to go. A good way to do this is to conduct a value stream mapping exercise, which involves identifying all the steps, resources, and inputs involved in creating and delivering your product or service to your customer. By mapping your current state, you can identify the sources of waste, inefficiency, and variation in your process, and prioritize the areas that need improvement.

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Tim N.

National Head of Planning - Operations & Manufacturing Partnerships @Greenstock
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From my personal experience, it's crucial to understand where you currently stand before embarking on any transformation. I would start by conducting a comprehensive analysis of existing processes, identifying bottlenecks, inefficiencies, and areas for improvement. This initial assessment provides the baseline for your lean journey, enabling you to set realistic goals.

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Thiago Loretti

Gerente de Qualidade, Sustentabilidade e Processos | Professor Lato Sensu na Funda??o Assis Gurgacz | Pesquisador de Kaizen | Master Black Belt em Lean Six Sigma | Auditor Líder ISO 9001 e 14001
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It's tough... involves a lot of commitment and a good mindset. Scaling lean practices across an organization involves securing leadership commitment, starting with pilot projects, standardizing successful processes, extensive training, transparent communication, fostering cross-departmental collaboration, cultivating a culture of continuous improvement, gathering feedback for refinement, establishing key metrics for measurement, and ensuring a sustained, long-term implementation. This strategic approach ensures widespread adoption of lean principles, fostering efficiency and continuous improvement throughout the organization.

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2 Define your vision and strategy

Once you have a clear picture of your current state, you need to define your vision and strategy for scaling lean practices. This means setting your overall objectives, aligning them with your customer needs and expectations, and communicating them to your entire organization. Your vision and strategy should also include the key performance indicators (KPIs) that you will use to measure your progress and success. A common framework for defining your vision and strategy is the Hoshin Kanri or policy deployment method, which involves cascading your goals from the top level to the operational level, and ensuring alignment and feedback throughout.

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Tim N.

National Head of Planning - Operations & Manufacturing Partnerships @Greenstock
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With a clear understanding of your current state, articulate a compelling vision for what a lean organisation looks like in your context. Develop a well-defined strategy that outlines the specific goals, milestones, and key performance indicators that will guide your transformation. Ensure that this vision aligns with the broader organisational objectives.

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3 Train and empower your people

Scaling lean practices requires not only changing your processes, but also changing your culture. You need to train and empower your people to embrace lean principles, tools, and techniques, and to apply them in their daily work. You also need to create a culture of continuous improvement, where your people are encouraged to identify and solve problems, experiment with new ideas, and learn from their failures. To train and empower your people, you can use various methods, such as coaching, mentoring, workshops, simulations, gamification, and online courses.

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Tim N.

National Head of Planning - Operations & Manufacturing Partnerships @Greenstock
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I can’t stress enough that importance of culture in driving a successful lean transformation program. Lean practices require a cultural shift, and your employees are at the heart of this change. Invest in training programs that equip your teams with the necessary skills and mindset to embrace lean principles. Empower them to identify problems, suggest improvements, and take ownership of the changes. Encourage a culture of continuous learning and improvement.

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4 Implement and standardize your practices

Once you have trained and empowered your people, you need to implement and standardize your practices across your organization. This means applying the lean tools and techniques that are relevant and effective for your specific process, such as 5S, Kaizen, Kanban, Poka-Yoke, or SMED. You also need to document and share your best practices, so that they can be replicated and improved by others. To implement and standardize your practices, you can use various methods, such as audits, checklists, visual management, gemba walks, and huddles.

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5 Monitor and review your results

Scaling lean practices is not a one-time event, but a continuous cycle of improvement. You need to monitor and review your results regularly, using the KPIs that you defined in your vision and strategy. You also need to collect and analyze data, feedback, and lessons learned from your implementation and standardization efforts. By monitoring and reviewing your results, you can identify the gaps, issues, and opportunities for further improvement, and adjust your actions accordingly.

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6 Celebrate and recognize your achievements

Scaling lean practices is not only a challenge, but also a reward. You need to celebrate and recognize your achievements, both as individuals and as teams. You also need to acknowledge and appreciate the efforts, contributions, and learnings of your people, and provide them with the support and resources they need to grow and develop. By celebrating and recognizing your achievements, you can sustain and reinforce your lean culture, and motivate your people to keep improving.

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Tim N.

National Head of Planning - Operations & Manufacturing Partnerships @Greenstock
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One thing I’d recommend is to begin implementing lean practices in a controlled manner. Start with pilot projects to test your strategies and gather data on their effectiveness. Once proven, standardise these practices across the organization, ensuring that everyone follows consistent processes. Lean tools such as value stream mapping and 5S & visual management can be instrumental in this stage.

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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?

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Tim N.

National Head of Planning - Operations & Manufacturing Partnerships @Greenstock
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Always acknowledge and celebrate milestones and achievements. Recognise and reward individuals and teams who contribute to the success of your lean initiatives. This fosters motivation and sustains the momentum for continuous improvement. Regularly assess your progress, adapt your strategies, and remain committed to the lean journey as a long-term, ongoing process.

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What is the best way to scale lean practices across your organization?

1

2

3

4

5

6

7

1 Assess your current state

2 Define your vision and strategy

3 Train and empower your people

4 Implement and standardize your practices

5 Monitor and review your results

6 Celebrate and recognize your achievements

7 Here’s what else to consider

Lean Manufacturing

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What is the best way to scale lean practices across your organization?

1

2

3

4

5

6

7

1 Assess your current state

2 Define your vision and strategy

3 Train and empower your people

4 Implement and standardize your practices

5 Monitor and review your results

6 Celebrate and recognize your achievements

7 Here’s what else to consider

Lean Manufacturing

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