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Q. What factors are necessary to be successful with lean? Answer in 500 words

Answer 1

Lean manufacturing is a systematic approach to production which focuses on minimizing wasteful activities and maximizing quality and productivity. This approach helps reduce cost, save material and strategically use labor and skill to achieve maximum output, while reducing errors and defects. It is implemented using various tools such as TPM( total productive maintenance) , Kanban system, one-piece flow, Kaizen, value stream mapping, poka-yoke, etc. These are customized for the particular firm and used. Lean was initiated by Toyota and successfully implemented such that they are reaping the benefits of lean. However, not many companies have been truly successful in implementing and maintaining lean for a long term. The following are the the factors that are necessary to ensure the company reaps the benefits of lean:

• The leader must be persistant. It must be noted that, one may not begin to reap the benefits of lean immediately. Lean is a long process. It requires persistance and hard work to make the project successful.
• Must be focused on making small improvements. Large leaps in improvements may not be consistent and easy to maintain. Thus, making small improvements to achieve overall target is applied in lean management.
• The communication must be good. There flow of information and knowledge sharing must enable all the employees to be active. Thus, there must be free communication.
• Employees and management all must be involved in implementation of lean. It is not one person or a group of individuals involvement which can ensure success. But, the entire organization must be involved in the change.
• Employee empowerment: employees must be given power and authority to take decisions regarding their respective tasks. They must be responsible for their activities and also be authorized to make decisions with respect to them.
• Training: adequate training of lean concept and it's tools must be provided to ensure employees understand the lean management better.
• Lean must be encouraged. The top management must support innovative thinking.
• Organizational change. In order to implement lean successfully, the organizational culture must undergo changes. It must become so free, that innovation, team work and co-operation, motivation, high - spiritedness is encouraged.
• Healthy competition. Employees are determined and motivated to improve efficiency in order to receive adequate appraisal.