Creating a Lean Culture, 3rd Edition

244 ◾ Creating a Lean Culture: Tools to Sustain Lean Conversions

documentation at final assembly. When attention shifted from schedule

completion to process quality and yield, the initial data were available

right away for Pareto analysis to reveal upholstery as the leading source of

interruption.

A second factor, and the most important, was a gradual change in the

mindset of leadership in the area, prompted by ongoing coaching by the

plant’s resident Lean sensei. As thinking shifted from schedule completion to

process quality and yield, the leaders began to ask why they had continuing

upholstery rejects. They took a systematic approach to discovering the

causes of the problems, and to eliminating them so the problems did not

recur. Once they ...