The Psychology Behind Lean Manufacturing

July 26, 2019 Off By Gertrude Evans

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It tookus about a week to actually finish the process. By the end of two days we had made a lot of progress, but it was essential that we complete the project entirely. I’m certain that things would have returned to “normal’ if we had not followed all five steps. It is very difficult to change a shop culture, but it can be done.

Immediate results. This is very helpful so that workers can see something positive happening. Since there is no time for them to object, their potential resistance is overcome by the nature of the blitz.

Do your supervisors “really” know how to be supervisors? Have you evaluated this aspect of your business? How many walk around with a coffee cup and a uncooperative attitude? How many are truly capable of training their staff? The gauge is how their employees react with them. Is there loyalty and positive attitudes? Or disgruntled, belligerent attitudes? Does the supervisor stand up and support the employees? Do they insure continued opportunity for training? What happens when an employee informs the supervisor of potential job related problems? Do they check it out or ignore it?

If you prescribe to the “lean soluciones y materiales” ideals, you know time management is essential. Poor time management or misused time management cost you money. Ex: $20.00 hourly employee(skilled trade) taking 30 minutes each day to sweep. At the end of the year, that employee cost you $2400.00 for sweeping, instead of using that same time to use his skill to make you money. The same job done by an $8.00 hourly employee whose standard job is labor, cost $960.00. Which is more cost effective? What if you have 10 employees making $20.00 sweeping? You tell me.

If you do not have any idea of where to start, then improve the productivity of your employees. Do some research inside your factory about the productivity of your employees. How many times they idled because of equipments breakdown? Which process of production that are the slowest?

As a conclusion, installing lean manufacturing system into your company is not enough to make it run properly. It is just like installing computer hardware without software. You will need to set the right mindset in your employees as this right mindset will be the software part of lean manufacturing system. To do this could take times but it will definitely give you much return in the future.