How can you handle unexpected changes to Lean Manufacturing deadlines?

1 Assess the situation

The first step to handle unexpected changes is to assess the situation and identify the root cause, the scope, and the urgency of the change. You need to gather accurate and relevant information from your team, your suppliers, your customers, and your stakeholders. You also need to evaluate how the change affects your current value stream, your key performance indicators, and your customer satisfaction. By assessing the situation, you can prioritize your actions, communicate your expectations, and allocate your resources accordingly.

2 Apply the PDCA cycle

The PDCA cycle, or Plan-Do-Check-Act, is a core tool of lean manufacturing that helps you implement continuous improvement and solve problems. To handle unexpected changes, you should start by defining the problem and setting objectives. Then, develop an action plan and execute it while monitoring the results. Next, compare the results with the objectives and analyze the data to identify gaps and opportunities for improvement. Finally, implement the improvements, standardize the process, and share best practices. By applying the PDCA cycle, you can adapt to the change, learn from the experience, and prevent recurrence.

3 Involve your team

Your team is your most valuable asset in lean manufacturing, as they are the ones who perform tasks, identify wastes, and suggest improvements. To handle unexpected changes, it is important to communicate the change clearly and transparently, explaining the reasons, goals, and impacts. Additionally, empower your team to make decisions, take actions, and provide feedback. Encouraging collaboration, sharing ideas, and supporting each other can foster a culture of trust, engagement, and innovation. Lastly, recognize your team's efforts, achievements, and contributions for their hard work.

4 Review your processes

Unexpected changes can reveal weaknesses and inefficiencies of your processes, as well as new opportunities for improvement. Therefore, it's necessary to review your processes regularly and systematically by using lean tools such as value stream mapping, 5S, Kaizen, and Poka-yoke. Value stream mapping is a visual tool that shows the flow of materials and information from supplier to customer. 5S is a method that organizes the workplace into five steps. Kaizen involves small and frequent improvements based on feedback and suggestions of workers. Poka-yoke is a technique that prevents errors and defects with simple devices or mechanisms. By reviewing your processes, you can reduce waste, optimize flow, and improve quality.

5 Seek feedback

Feedback is essential for lean manufacturing as it helps you measure your performance, identify your gaps, and improve your processes. To gain the most value from feedback, you should seek it from customers, suppliers, and stakeholders. Your customers are the ultimate judges of your value proposition and can provide insights into their needs, preferences, and satisfaction levels. Suppliers are your partners in delivering value and can offer information on their capabilities, availability, and reliability. Stakeholders are your supporters and influencers and can give you advice, guidance, and resources. By seeking feedback from these different sources, you can align your goals, expectations, and actions with your value stream.

6 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?