Lean Transformation Process (10-point plan)

1.    Assess the commitment and level of Lean knowledge with company leadership and staff. (Lean implementation is a people process that always needs to be led by leadership)

2.    Walk the plant floor in reverse and value stream map the process.

3.    Establish the “Pacemaker” operation, determine takt time, and recognize where to flow and where to pull.

4.    Identify quality and equipment down time concerns that inhibit the process flow.

5.    Stabilize the process- Lean training, team building, quality at the source, TPM, and process kaizen.

6.    Establish a visual factory through 5-S.

7.    Drive standard work at all levels, including a layered audit process.

8.    Make materials flow- Level schedule (volume, mix, and sequence), with established pitch sizes, and kanban connection mechanisms.

9.    Pick the projects to work on first and appoint teams with clearly defined goals and a management review process.

10. Create an environment for problem solving (A-3) and continuous improvement.  Expect results quickly!