The Practical Improvement Series: Episode 5: The Main Tools of Lean

Melissa’s questions to Adriana: What are the main tools of Lean?
In Episode # 3 of this Series, we talked about some of the most important aspects of the process.
We dived deeper into the process that is actually happening, and how it often differs from the one that has been deployed.
We revealed some of the reasons why this happens, and we promised to uncover what we can do to curb these wasteful practices in our processes.
The question Melissa asked me this time will be our spring board to get into the actionable and practical tools of Lean/Continuous Improvement for problem solving within the process.
First, I want to re-emphasize the following,
People are doing the best they can.
I know. It sounds like a contradiction. If people are already doing the best they can, why then are there inefficiencies that can be improved?
Let me elaborate this statement.
People are doing the best they can with…
The Tools
The Training
The Motivation
The Knowledge
The Beliefs
The Experience
The Responses to the Environment
The Processes
They have. (And many other factors.)
That is why empowering people with the Lean/Continuous Improvement Tools is so important. It allows people to do the best they can at a higher level - every time.
Now, without more preamble, let’s go deeper.
Remember the Shadow Processes (Workarounds & Shortcuts)?
People might be skipping a step or two, doing fixes on the fly without documenting them, or relying on tribal knowledge.
The Lean Solution:
- Go to Gemba.
Gemba is a Japanese word that means “The Real Place”. Gemba is where the actual value is created, where the work is done.
Without doing this, we cannot see what is really happening in the process, and problems will be detected when they have already become bigger.
- Map the Real Process with Current State Value Stream Mapping (VSM)
Value Stream Mapping or VSM is a powerhouse tool of the Lean/Continuous Improvement Methodology. It brings visibility into what the real process looks like, not the assumed one.
More importantly, it also uncovers the
Wastes that are happening in the steps of the process.
With this valuable information, we can use other Lean/CI Tools to solve costly problems in the process.
What about the
Emotional Undercurrents (Fear & Blame) problem?
This issue deserves a lot of attention if we are to get anywhere trying to solve the other ones.
After all, what we are trying to do with Lean/CI is to build
Empowered Problem Solvers who use the tools to eliminate waste, improve efficiency and effectiveness in the operation, and enhance the value to the customer.
The symptoms are clear: silence in meetings, problems are not raised, and remain hidden; when something goes wrong, there is blame, and managers believe that "people should know” because they were told
once.
The Lean Solution:
-Build Psychological Safety.
The lack of Psychological Safety is one of the most costly mistakes that organizations make.
It creates a disconnect that leads to high turnovers, it diverts people’s valuable resources to feeling safe and not use them for innovation and improvement, and it seeps away productivity, promoting quiet quitting.
When the culture of an organization normalizes the concept of “Problems as Opportunities for Improvement” and managers walk the talk by removing the blame game/ finger pointing/ negative reinforcement cycle, people are encouraged to bring up issues earlier, which leads to faster improvement and less cost.
Change the course of action by focusing on the process, not on the people.
Ask the question, What in the process is causing this issue?
Practicing the Lean Principle
Respect for People is the shortest and most effective path to empower your teams to become owners of their processes and overcome the Fear and Blame problem.
Once people are willing to come to you with problems because you have built trust and respect that goes beyond the surface, you can use Lean/CI Tools such as Daily Lean Huddles, Root Cause Analysis with the Team, (Fishbone Diagram/ 5 Whys) to solve problems more effectively.
Remember, whatever we do in our processes, the main objective is
serving the human so their value can be realized in better ways, using less of their valuable resources, and nurturing their accountability for their processes, because they have become the owners, not merely the operators of their processes.
It all pays off in very measurable, [less waste = more profit $$], and less tangible ways, [people stay and give more of their value, willingly].
In the following episodes, we can start unfolding each tool and show about their implementation.
Be Well & Joyful. 😊
Adriana C. Torres
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