How can you scale experiments in lean manufacturing?

1 Define your problem and hypothesis

Before you start any experiment, you need to have a clear problem statement and a testable hypothesis. A problem statement is a concise description of the gap between the current and the desired state, the impact of the problem, and the stakeholders involved. A hypothesis is a tentative explanation or prediction of how a change or a solution will affect the problem. For example, a problem statement could be: "Our defect rate in the assembly line is 10%, which causes delays, rework, and customer complaints." A hypothesis could be: "If we implement a 5S system in the assembly line, then we will reduce the defect rate by 5% in one month."

3 Plan your experiment design and execution

The next step is to plan how you will design and execute your experiment. You need to define the scope, duration, frequency, and sample size of your experiment. You also need to determine the variables, conditions, and controls that will affect your experiment. For example, you could use a randomized controlled trial (RCT) to compare the 5S system with the current system, or a before-and-after design to measure the difference in the defect rate before and after the intervention. You also need to plan how you will communicate, document, and report your experiment results and findings.

4 Run your experiment and collect data

The fourth step is to run your experiment and collect data. You need to follow your experiment plan and ensure that you adhere to the ethical, safety, and quality standards. You also need to monitor your experiment progress and performance, and make adjustments if needed. For example, you could use a checklist to verify the compliance and consistency of the 5S system, or a feedback form to gather the opinions and suggestions of the workers and managers.

6 Learn and share your insights and actions

The final step is to learn and share your insights and actions. You need to reflect on your experiment results and findings, and identify the key learnings and implications. You also need to share your insights and actions with your stakeholders, and solicit their feedback and input. For example, you could use a report or a presentation to summarize your experiment process, outcomes, and recommendations, or a workshop or a meeting to discuss the next steps and actions.

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?