Lessons from a Lean Consultant

Introduction

At first glance, lean manufacturing appears to be a magic solution for the numerous problems experienced in many factories. A powerful and effective improvement philosophy, lean manufacturing can prevent company failure—or catapult a business into the status of a world-class organization. It’s well known and widely accepted that many improvements—such as enhanced productivity, improved quality, shortened lead times, and reduced costs—are the direct result of employing lean manufacturing methodologies.

Without a doubt, embarking on a lean journey is a wise choice as well as a bold one. It is important to recognize, however, that not all stories end in success. Although few people in the manufacturing environment realize it, there ...