MAKE PROCESS VISIBLE and predictable

A Non-Lean environment is where ...

Mediocre Processes are managed by Amazing People

Whereas a Lean Environment is where ...

Amazing Robust Processes can be staffed with any one!!!

So why are developing Robust Processes so difficult? In most cases people have become victims of their environment. Over time complexity has crept into the process making it harder for new people to learn and typically the process takes longer and has unpredictable outcomes.

Look at the anatomy of a car ... If we used one employee to build an entire vehicle. That employee would need to possess many skills to complete the task, for example; be a welder to assemble the frame, a skilled assembler to build the engine and attach other drive train components, an upholster to create the interior, a painter for the exterior ... The list goes on and on ....

Just imagine f you could find such a multi-skilled employee how much would it cost and to control them to meet your design requirements will be like training a thorough-bred horse.

Henry Ford was brilliant ... He knew that to be effective, cost positive and predictable he needed to take tasks and begin to break them down into small manageable components. The sum total of the task to build a car was still smaller than having an artisan build your complete car ... But with a difference we had individual specialists not generalists and many eyes to contribute continuous improvement ideas.

Even McDonalds has mastered the art of work break-down and even included the numerous use of andons to control the process.

TIP !! You need to observe every process and break it down to the simple tasks.

Even after you have a list of task continue to break it down to the very minimal

and simple of task elements.

Look especially at your office and administrative processes Since little has been done to Lean out these processes ... huge opportunities exist for cellular methodologies and

single piece flow.

Next look at how to create flow within the process. A great way to accomplish this is the adoption of Timed Delivery Routes since it accomplishes a couple of things:

First, Timed Delivery Routes maintain employees focused at their work stations while the materials are being conveyed or advanced through the process. Second, and probably more important is that they will establish a cadence within your organization.