Sunday, March 10, 2019

By Diane Foster


Companies are always looking to streamline their processes. Making sure that the resources are well utilized right down to the last bit. A lean manufacturing consultant uses tolls to identify and eliminate waste steps in the process. This is aimed at continuous improvement. The exercises are geared towards averting resources from redundant activities so that the useful ones can have a chance to work better.

It is easy to fool oneself into thinking that literature and vlogs will make one into an overnight expert. It does seem pretty easy. However, there is a technique to it. One must understand that the tools only account for 20% of all of it. The remaining 80% is all about manipulating the internal environment. Using the culture of the company to ensure the success of such exercises. It is more about where the tools are applied than the tools themselves.

One of the biggest reasons to hire outside help as opposed to self-handling is an experience. These professionals work hard and long in the industry. To gain some sort of natural knack for the craft. To have the ability to apply creative solutions in addition to the traditional tools. They have undergone training. They have studied many programs. They have vast experience in the field and the experience they would bring into the company.

When one is proofreading their own work, it is very easy to miss typos and mistakes. There is a condition called typo blindness. However, if another person takes a look at the work. They may see the mistakes within minutes. The fresh eyes help recognize waste activities that one would otherwise miss on their own. Where one will see everything as necessary, the fresh perspective will be useful.

When looking for a sensei, one may start by looking at companies that have benefited from the exercise. A successful program is a good guide. Find the people who were responsible for the success. That is how one develops their own list of candidates. The selection process must be rigorous. This person will be making some major changes in a company. One must ensure to pick someone who is qualified to do that.

There are different kinds of professionals. Processor, flow and Kaikaku. The first aimed at specific problems. The solutions will be targeted and bespoke to that specific issue. The second is aimed at whole streams or lines in processes. The last is about a general picture. The specialist looks at all processes as a whole. This will also help prescribe a set of solutions. It is better when one knows how to focus their energies.

There is no prescribed guide to finding a good sensei. However one should keep the missions in mind. The sensei should have two missions. The first being problem-solving. Through audits and analysis, the sensei will help diagnose. The second mission is productivity. This is done by application of improvement methodologies.

This exercise has very little to do with textbook solutions and prescribed actions. It is about learning by doing. The latter can cause quite a bit of friction between the sensei and the employees. For success and seamless work, there should be trust and respect.




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