“Western” Lean, an evolutionAD Net 19/01/2016
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« Western » LEANan evolution
19/01/2016
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Luc Van LandeghemPresident IIBLC®
Agenda
• Phase 1: techno• Phase 2: socio• Phase 3: socio-techno
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“Western” Lean, an evolutionAD Net 19/01/2016
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PHASE 1TECHNICAL (TOOLS)
± 1990 - ± 2010
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Lean toolboxSMED
Standardised
work
Batch Reduction
Teams
Quality at Source
5S
Visual Systems
Layout
planning
POUS
Cellular/FlowPull/Kanban
TPMValueStreamMapping
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“Western” Lean, an evolutionAD Net 19/01/2016
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Fact• Study University Ghent (BE)• Period of 3 years (Dec. 2009-Nov. 2012)• 23 SME
– Novice in Lean or– Renewed effort
• 6 countries(North Sea region)– Belgium– UK– Netherlands– Sweden– Norway– Germany
Fact
© H. Van Landeghem-K. Bauters-V. Limère Ghent University
“Western” Lean, an evolutionAD Net 19/01/2016
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Fact
© H. Van Landeghem-K. Bauters-V. Limère Ghent University
Fact
© H. Van Landeghem-K. Bauters-V. Limère Ghent University
“Western” Lean, an evolutionAD Net 19/01/2016
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PHASE 2SOCIO (HUMAN)
± 2010 -
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Fact• 70% employees not
engaged – 52% not enthusiastic– 18% truly unhappy
• 30% love their job• (15.000 respondents)• Direct link to
– Accidents– Faulty products
• How about Europe?
“Western” Lean, an evolutionAD Net 19/01/2016
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Fact
• Liker and Rother (2007):– 70% adoption rate (US plants)– 2% fully achieved objectives
• P. Hines (2012):– 70% of all companies fail to make Lean a
sustainable source of productivity improvements
Conclusion
• P. Hines– “the reasons why so many companies fail to achieve the full Lean
potential is due to management issues, such as lack of Strategy alignment, Leadership and Engagement”.
• Study University Ghent• ....
“Western” Lean, an evolutionAD Net 19/01/2016
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People/Management
• Need for knowledge of mission-vision– Rotations? Handover– Lean is NOT “the next quarter”– Lean is NOT “a menu”– Lean is NOT “cost-saving”– Need for an improvement PLAN
• Change of paradigm– Employees are part of the solution– Confidence– Mgr. as coach
• GEMBA walks• What can I do for YOU?
People/Management
• Continuous support– Put your money where your mouth is– Board meetings– Failure IS an option (©Mythbusters)
BUT: • Is management READY for the change?
– Necessary competences?– Formal education?
“Western” Lean, an evolutionAD Net 19/01/2016
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People/Employees
• Part of the process• Training
– Already acquired? (elsewhere?)– If/when necessary
• Long-term program– Saturation?– Intimidation?
• Practice, practice, practice!– Visible results– Celebrate success
Tips
• Sometimes you better wait!!– < frustration– < “Chronicle of a Death Foretold” (G. Márquez)
– < resistance next project• Think big/start small
– Principle of the oil slick• Formula of the final result:
Rs = Qs x AResults = Quality Solution x Acceptance
“Western” Lean, an evolutionAD Net 19/01/2016
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© International Independent Board for Lean Certification® 2009- All rights reserved
PHASE 3SOCIO-TECHNICAL
± 2013 -
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“Western” Lean, an evolutionAD Net 19/01/2016
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Socio-technical system
• “Employee-supportive Lean”
– D. Rodriguez doctoral study 2015
• Integration of both approaches
• Maximizing results• Phased approach
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Socio-technical characteristics
• Training for everybody• At the desired time and pace• Employees empowerment and
participation• Problem solving at lowest level possible• Two-way management (Hoshin Kanri)• Using correct tools (at appropriate time)
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“Western” Lean, an evolutionAD Net 19/01/2016
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Extra SMED
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Airbus Industries 2015
Extra visual mgt.
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What’s wrong with this picture??
“Western” Lean, an evolutionAD Net 19/01/2016
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