Book:Toyota Production System: Beyond Large-Scale Production

Posted October 11th, 2011 in Lean Management Books by Vivek Naik

In this book, Taiichi Ohno — inventor of the Toyota Production System and lean manufacturing — shares the brilliance that sets him apart as one of the most disciplined and ingenious thinkers of our time. Combining his frank insights with a thorough analysis of Toyota’s attempts at lean production, Ohno’s book explains how lean principles can improve any production-oriented enterprise. A chronological and thoughtful description of just-in-time and lean manufacturing, this work a must read for all students of human progress. On a more practical level, it continues to provide inspiration and instruction for those seeking to improve efficiency through the relentless elimination of waste.

The Two Pillars of Lean Management

Posted October 3rd, 2011 in Lean Manager, What is Lean Management by Vivek Naik
Pillars of Lean Management

The Two Pillars of Lean Management

Lean management derives its values from 2-key principles of lean; Respect for People and Continuous Improvement.

Continuous Improvement:  

A lean manager is focused on solving problems incrementally. Each solution is an experiment which helps in the learning process and paving the path to the next level.Small improvements followed by time of stability and then again a small improvement , is a cycle that is preffered in a lean environment . this form of  small changes are easier to manage without much disruption to the suppoorting proceses like material supply to the line.

Respect to People :

As easy as it seems this by far has been the most difficult things to understand . It has often been described as an important quality  that any lean manager should posses . A lean manager respects people by giving them the authority to solve their problems .This way lean manager uses the knowledge of the people who actually add value to the process and also able to get buy in by engaging all the employees . This does not mean that a lean manager completely disconnects himself from problem solving. He guide his people to solve their problems by asking the right questions ,till they find the root cause.


What is lean management?

Posted September 21st, 2011 in What is Lean Management by Vivek Naik

Lean management is an important part of lean thinking. As we implement lean in any organization the traditional way of managing does not guarantee right focus nor help sustaining lean initiatives. If no action is taken to change the way we manage process, people and products we are likely to see failure of lean implementations. Many people on lean journey fail to apply lean in a holistic manner. Usually they start with applying tools without proper guidance and leadership the company cannot move to the next level. Thus a management system that specifically meets the needs of a transforming organization is very much essential.

So what is traditional management and why does it fail to sustain Lean?
One of the main characteristic of traditional management is that it is resulted oriented. Is it good or bad to be result oriented? It is not bad to have goals but once people stop caring about how to get there rather and only focus on end result, that’s when we have a problem. This leads malpractices like expediting orders, over production, and excess inventory. You must be wondering how management leads to these problems. If you are in any manufacturing organization you will be able to relate to this problem better. Here are few examples:

  • How many times have you expedited the order by doing overtime just because you had to meet the same day delivery goal.
  • Have you kept producing even when there was no demand just because just because you needed to show better utilization of the operators?
  • Do you keep excess inventory to hide the inefficiencies related to your process or machine breakdowns?

These are just few but are common problems that will help you relate to the problem created by mismanagement. The problems are so easily accepted as a part of our daily life, that we hardly question these practices. Only with right mindset and proper management you can facilitate the change.

What is lean Management?
Lean is all about customer focus. Value is defined by the customer and we develop and maintain processes to provide this value. Processes are run by people. Only support and proper leadership and guidance you can drive your people to continuously improve the processes that add value to the customer. The management system that helps you to achieve this is a Lean Management system. Lean Management system uses various tools to connect the purpose (Providing value to customer) to the process and people. Some of the lean management tools which are commonly used are Leader standard work, visual control boards, and daily accountability.
The tools itself are not effective unless used with right mindset. There is a lot of work needed to be done at individual level for the mangers to become lean managers. To start with lean management we have to start developing managers in to “Lean Managers”. What are you doing to become a lean manager?