Interesting Discussion Lean Manufacturing Concepts - Is 'Lean' hype?

Is 'Lean' hype?


  • Total voters
    61
  • Poll closed .
W

WesCharley

I thought I answered the question about how I handle potential clients that are not in need of my help. I would not sell my services to a client who did not need them. It goes back to that little thing called business ethics which would be an entirely different discussion. I just haven't run into that issue as of yet.

Has anyone read the article Learning To Lead At Toyota by Steven Spear?
It is a very interesting read. Toyota has been building and improving it's productions system since the late 1800's yet it still spends weeks, months and sometime years training it's new managers in their production system on the shop floor. How good of a job do you guys feel US companies that practice lean do at getting their managers that type of hands on training? Has anyone here had that extent of training or at least an effort to get them on the floor learning lean before they assumed their new role?
 
Elsmar Forum Sponsor

Stijloor

Staff member
Super Moderator
<snip> Has anyone read the article Learning To Lead At Toyota by Steven Spear?
It is a very interesting read. Toyota has been building and improving its productions system since the late 1800's yet it still spends weeks, months and sometime years training its new managers in their production system on the shop floor. How good of a job do you guys feel US companies that practice lean do at getting their managers that type of hands on training? Has anyone here had that extent of training or at least an effort to get them on the floor learning lean before they assumed their new role?
Learning to Lead at Toyota.

Stijloor.
 

Attachments

J

JkelleyCDS

I performed a Lean Activity when it came to part transportation waste recently at my new company. I reduced the distance a part traveled by over 23%. When it comes to 400 units a year, that 23% per unit can add up and save a lot of time which equals $$$. It was a spaghetti diagram or factory layout where we tracked the multiple stations parts would go for no reason. The part would sit, cycle time would increase, etc. By rearranging the work floor layout a continuous product flow was kept and these "muda" or wastes were reduced.

Hope this gives you an example of how lean principles can be put to good work.
 

Marc

Hunkered Down for the Duration
Staff member
Admin
Thread with Poll started 17th January 2003, 12:21 PM by mike101338.

Poll Closed on 11 May 2008 by Marc.
 
P

palmer

Lean isn't hype, it is one of several ways to describe an ideal or to follow a set of objectives where you stay organized and efficient.:nopity: Do the right things, at the right times, the right way.
 

tongxiaozhi

Involved In Discussions
I don't see it as a rant - "expression of frustration" is the euphemism I hear lately.

I suspect that when failures of TQM, Zero Defects, and similar programs often labeled "flavor of the month" are examined, the root cause of failure will be attributed to management insincerity or to complete "cluelessness" on the part of managers that their role has to be real and ongoing.

The moment folks with real authority [bosses] in an organization think the program will run by itself without regular review by bosses is the moment the program begins to deteriorate. Successful programs require commitment and involvement by the bosses. Without commitment and involvement by bosses, it soon becomes apparent to employees the route to getting noticed and rewarded is NOT in the Quality program.

Thus, the problem lies not with the program, but in lack of knowledgeable implementation and involvement by the bosses.

Anyone out there concur or differ with this view?
I fully agree with you on this. We have been doing lean for more than a year but turns out to be a total failure. Management just accounted on lean manager to make the whole change. Doing lean is a very long and sometimes frustrating journey. Sometimes, we have to sacrifice short term gains for long term objective. Management involvement and deep commitment are vital to change the culture and maintain the gains. If management views it as "program of a moth" it will be viewed so by employees. In the end, new ways cannot be maintained and the organization gradually declines back to the old way. It is easier to learn and master the tools, like 5S, SMED, standard work than to change people's mind. It is all about culture change.
 

kgott

Quite Involved in Discussions
Hey guys and gals, I need some help here! The company I work for is in need of change. More than half of the work force has been here for greater than 10 years. Although that produces some very good things, it also creates some negatives. One of those is the introduction of new concepts. The last "lean consultant" I had in here to offer ideas on where we should start left looking like :confused: . Can anyone share with me the success stories witnessed at your locations? Also, anything you did to help sell the ideas to upper management, then to the rest of the staff.
Thanks,
Mike
Perhaps calling it lean is what did it. There was once a wonderful thing that went under the letters TQM, and in my view, it got killed off by something called Total Quality Management whatever the heck that meant ???????????
 
B

Bugoll

Lean and Six Sigma are methodologies which work together.
Six Sigma focuses on process variation (Variation reduction, Scrap/ Rework elimination, process optimization, SPC). Lean tools focus on process speed (Waste elimination, Work standardization).
Not all project improvements need both these methodologies but when we have a complex task for optimisation: Six Sigma considers process flow and capacity ? Lean gives additional tools (Value stream map, 5S, Spaghetti diagrams, Time value chart, etc.).
Thus 'Lean' isn't hype - is a set of old-established methods for process improvement.
 

Mikael

Quite Involved in Discussions
Or perhaps we should have asked what should the word have ment. The word make sense only as an opposition to a buffer approach when talking stocks, and yes that can include a full supply chain view. Still it should have been "just" a stock concept and the word would have had meaning and a legitimate word to use in the discussion of a stock approach, where lean would not always be the best choice.
Even for the founders it was not sexy enough so it was broaden out.
Today it means everything and nothing within everything that have any kind of cut cost touch on it.

Lean today is ****, bullshit and sometimes very bad for business.
The original book that people seems to refer to is just a bla. bla. story about manufacturing/sector making improvements, fair enough, but dont call it real science and dont call it a real theory, call it a sweet story.
There is nothing in Lean that have not already been said within theory from beyond the buffer/lean distinction. That is there is nothing fantastic or revolutionary about lean.

With an education in Supply Chain Management and before that philosophy, I can easily pull apart the assumptions within the original lean concept. Yes there can be some sweet thumb of rule things, but if you want to start take things more serious you must go beyond lean.


I see a similiar problem with "Disruption", nobody take their time to actually search on Christensen and disruption, to know that he is very clear on the fact that it is not just a new term for innovation or revolutionary breakthrough.
Besides a time issue, there is not much new in the concept of disruption that we did not already knew from the business theory history. Being aware of different market segments have always been basics within business. With disruption we have a name for a specific scenario there and that is fine, but today it kind of mean innovation, breakthrough or radically news, unfortunately.
 

Bev D

Heretical Statistician
Staff member
Super Moderator
I don't know Mikael. Your explanation of why you believe Lean to be ***** is not very descriptive of true Lean (Toyota Production System).

Certainly there are MANY hacks out there who pass off some pieces and parts of TPS/Lean as "Lean" but they do not represent what true Lean is. Lean isn't just Kanban or 5S or mapping or the visual workplace or Kaizen. It is like a tapestry; when you take one or two pieces out of the tapestry the pieces fail because they are no longer supported by the interwoven threads of the whole tapestry.

It takes deep understanding of TPS/Lean to really understand it and implement it properly. I would say that partial implementations are therefore doomed to fail. Not because of any inherent weaknesses in TPS/Lean, but because of the incomplete and incorrect method of implementation.

Perhaps you have an incomplete understanding of TPS/Lean? Could you expand on your thoughts?
 
Thread starter Similar threads Forum Replies Date
T Examples of Mura and Muri to be used in Training - Key Concepts on Lean Manufacturing Training - Internal, External, Online and Distance Learning 10
S Lean Manufacturing Concepts Discussion Lean in Manufacturing and Service Industries 126
J Lean MFG (manufacturing) process and Work order templates Lean in Manufacturing and Service Industries 6
B Looking for Lean Manufacturing Articles in Spanish Lean in Manufacturing and Service Industries 4
E Lean Manufacturing in Oil & Gas Industry Lean in Manufacturing and Service Industries 4
O Lean Tools in Labour Intensive Manual Manufacturing Lean in Manufacturing and Service Industries 20
F Looking for some type of training on Lean Manufacturing video or web training Lean in Manufacturing and Service Industries 7
C Availability of Lean Manufacturing Training The Woodlands TX Training - Internal, External, Online and Distance Learning 4
O Lean Manufacturing Implementation Lean in Manufacturing and Service Industries 7
L How Lean Can Manufacturing Get? Lean in Manufacturing and Service Industries 7
C Lean Sigma Manufacturing Handoff Package Contents FMEA and Control Plans 8
A Lean Manufacturing in the Food Industry Lean in Manufacturing and Service Industries 4
R Demand Flow Technology vs. Lean Manufacturing - Same method with just another name? Lean in Manufacturing and Service Industries 9
C Lean Manufacturing Implementation and Training Materials - Recommendations wanted Lean in Manufacturing and Service Industries 6
S Lean - Ways to Measure Equipment Flexibility - Flexible Manufacturing System (FMS) Lean in Manufacturing and Service Industries 2
Z Lean Manufacturing Conferences - Could anyone suggest some good conferences? Lean in Manufacturing and Service Industries 1
P Where can one get trained in belts and lean manufacturing? Professional Certifications and Degrees 10
B Quality & Lean Written Quiz on terms and defintion of Quality and Lean Manufacturing Software Quality Assurance 8
R Beyond Lean manufacturing - Operation management / Performance improvement Lean in Manufacturing and Service Industries 1
B Cell Manufacturing - Project to implement lean manufacturing principles Lean in Manufacturing and Service Industries 4
M Lean To Attack Manufacturing Wastes Lean in Manufacturing and Service Industries 8
hogheavenfarm Lean manufacturing seminars in NY/CT area? Training - Internal, External, Online and Distance Learning 8
C HMLV Lean Questions - PCB manufacturing industry Value Stream Mapping Lean in Manufacturing and Service Industries 3
T At what stage in a company's life can you introduce Lean Manufacturing Principles Lean in Manufacturing and Service Industries 12
A Where does the Lean Manufacturing philosophy / tool set come from? Lean in Manufacturing and Service Industries 30
E Lean Manufacturing Presentation - What should I include? Lean in Manufacturing and Service Industries 13
J Lean Manufacturing without stability - Rate it 1 to 5. Lean in Manufacturing and Service Industries 4
D Lean 6 Sigma book recommendations for young, inexperienced manufacturing Engineers Book, Video, Blog and Web Site Reviews and Recommendations 4
A Does anyone know some metrics can I use to measure Lean Manufacturing? Lean in Manufacturing and Service Industries 8
J Lean Manufacturing using the FMEA? Lean in Manufacturing and Service Industries 4
P The Significance of Lean and Six Sigma Outside Manufacturing - Thesis Questionnaire Six Sigma 0
S Student needs advice on his career in the field of Lean Manufacturing and Six Sigma Career and Occupation Discussions 14
S Student requests help on Lean Manufacturing - Masters in industrial engineering Lean in Manufacturing and Service Industries 14
A What is the expectation of Lean manufacturing plans in Visteon specific requirements Customer and Company Specific Requirements 0
P Definition Lean Manufacturing - Definitions of (thesis assignment) Definitions, Acronyms, Abbreviations and Interpretations Listed Alphabetically 5
R Surveys about Quality Management and Lean Manufacturing The Reading Room 0
M Lean Manufacturing Overview Aimed at Management Lean in Manufacturing and Service Industries 4
A VSM (Value Stream Management) for service industry - Lean Manufacturing Lean in Manufacturing and Service Industries 4
Wes Bucey Body of Knowledge for Lean Manufacturing Lean in Manufacturing and Service Industries 47
S SAE Jrr 003 (RR-003?) - SAE J4000 - Lean Manufacturing - Status Evaluation Various Other Specifications, Standards, and related Requirements 9
M Lean Manufacturing, SAP and 8.2.4 - No records indicating release of product ISO 9000, ISO 9001, and ISO 9004 Quality Management Systems Standards 1
A Any folks have article, insight about Lean / Lean manufacturing to share? Book, Video, Blog and Web Site Reviews and Recommendations 12
WALLACE LEAN 'manufacturing' within a Leasing environment Lean in Manufacturing and Service Industries 6
G Low Hanging Fruit - Lean Manufacturing Ideas for a Job Shop Lean in Manufacturing and Service Industries 9
A TS 16949 Clause 6.3.1 and Lean Manufacturing - Any guideline for implementation? IATF 16949 - Automotive Quality Systems Standard 3
P Lean Manufacturing - Eliminating Inspection - Can Quality Survive? Lean in Manufacturing and Service Industries 49
A Linkage of ISO 9001:2000, ISO/TS16949 and Lean Manufacturing Lean in Manufacturing and Service Industries 19
Q Has Lean Manufacturing put on weight due to Middle Age? Lean in Manufacturing and Service Industries 14
A Lean Manufacturing - How do I change my company's Culture? Lean in Manufacturing and Service Industries 26
S Teams and Lean Manufacturing Lean in Manufacturing and Service Industries 20
Similar threads


















































Top Bottom