Training, a 5S campaign, a few new boards along the lines, and a year later, the production hall looks almost the same as before. Lean transformation assumes a different path: it starts with the problem that most hinders the company, changes management methods, and continues for years. Together with Leantrix, we explain what this path involves and how to ensure that the changes stick on the production hall.
Production reports show the numbers. The Gemba Walk reveals reality. This is one of the fundamental lean management practices, which involves managers going down to the shop floor and observing the process where it actually happens, instead of analyzing data from the office. It's a simple idea, but in practice, it requires discipline and skills that aren't acquired overnight.
No manager can see everything. An operator who spends eight hours a day on the same machine sees things that aren't visible from the office: minor hiccups, recurring problems, areas where something could work better. A plant that can gather and utilize this knowledge improves faster than one that relies solely on management's ideas.
Every production hall or warehouse has its own unwritten map. Regular employees know it by heart. They know which way the forklift goes, where the emergency exit is, and which areas to avoid. A new employee enters with zero knowledge of the space and must navigate it independently before learning all the rules of the area.
Attract the best employees with interior design and appropriate space signage! Safety, aesthetics, and creativity are the foundations of successful employer branding!
