Lean Implementation Plan
It is crucial that a robust plan is developed for every lean project to reduce uncertainty of requirements, schedule and investment. To ensure success, lean projects managed by Strahm S3 include the following phases:
- Define goals
- Assess the current situation
- Develop detailed implementation plan
- Execution
- Evaluation.
Goals are defined in the first phase of a lean transformation. Every lean project will target varying degrees of anticipated productivity improvement, quality improvement, inventory reduction, lead time reduction and floor space savings. The compilation of these improvement goals guides our team in developing the lean implementation plan for you.
The second phase is broadly defined as assessment. Assessments are leveraged to determine the benefits of applying lean methods, to prioritize improvements and to set the framework for a detailed lean implementation plan. Strahm S3 utilizes the six part lean assessment approach adapted from Henderson and Larco’s book titled “Lean Transformation” to evaluate the current state of operations prior to beginning a lean transformation.
Strahm S3's assessment includes:
- Workplace safety, order, cleanliness
- Just-in-time (JIT) production
- Quality management; empowered teams
- Visual management
- Pursuit of perfection
The assessment of JIT production includes current state value-stream mapping. The current state value-stream map illustrates the entire process prior to a lean transformation highlighting value and non value adding work. Finally, a future state value-stream map is developed in this phase, which guides development of the implementation plan and evaluation of progress in achieving a lean transformation. Typically, this phase will show that there is much inefficiency in the current processes with a potential to save large amounts of capital tied up in inventory, to reduce unscheduled overtime and to eliminate unneeded additions to overall lead time.
The detailed implementation plan is developed in the next phase of the lean implementation. The information gathered in the first two phases of the lean transformation form the basis of the detailed implementation plan. Areas or processes to be transformed are prioritized to begin in areas where early success is likely or significant gains can be realized, this initial process or area is called the model area. The model area is used to gain momentum by demonstrating results of lean principles and to train associates that will help guide further roll out. Detailed implementation plans include planning for layout optimization, process standardization, communication, training, execution and ongoing performance evaluation.
Execution is the fourth phase of a lean transformation. Sub activities of the execution phase include associate training, layout optimization, process standardization, quality improvements and material delivery changes. During this phase significant learning occurs regarding the individual processes that are being transformed by the lean project. It is often discovered during process standardization activities that associates spend a significant amount of their time walking and searching for parts and tools.
The final phase of a lean transformation is an overall performance evaluation. The initial goals are reviewed during the onset of this phase. This phase includes a close-out debrief to document lessons learned during the transformation to be leveraged for future lean projects. Finally, in order to sustain the benefits of the lean transformation periodic reviews of the future state value stream map are conducted and continuous improvement techniques are leveraged.
Strahm S3’s management team has a track record of substantial success delivering lasting and quantifiable results using lean principles. To increase the likelihood of success Strahm S3 leverages the following five phases for lean projects: define goals, assessment, develop detailed implementation plan, execution and evaluation. Successful lean projects include application of these phases, but continuous improvement is the key to sustaining advancements in lean service and manufacturing.