Integrating a structured problem-solving process in a lean project - Challenges and opportunities

Abstract

Many companies strive to transform their organizations into a Lean enterprise, only to experience short-lived gains. Lean holds the potential to significantly reduce costs, but considerable challenges exist that can prevent Lean initiatives from being sustainable. A typical approach is to concentrate primarily on Lean tools alone, without leveraging other foundational transformational components. For this reason, sustained benefits of Lean are often times not realized. A successful Lean initiative can produce sustainable gains by employing a holistic approach to implementing change. Specifically, a balanced focus on Lean tools, collaborative problem-solving and culture transformation represent three core components of any successful Lean transformation initiative. In addition, identifying tangible success measures that are aligned to these core components will keep the organization on track to becoming a high-performing, adaptive culture. This paper describes how Lean tools are used and integrated into IBM's 8-Step Structured Problem- Solving Process. Also described are experiential learning activities that are used in activity-based workshops to train Lean "Core Teams" to shepherd a Lean enterprise in their own organizations. Critical success factors for a successful Lean implementation and examples of successful Lean initiatives are also explained. Copyright© (2009) by the American Society for Engineering Management.