Start with the basics

This quote always makes me chuckle because it’s so true. According to Mr. Shingo, the Toyota production system is 80% waste elimination, 15% production system, and only 5% Kanban.

Yet so many self-proclaimed “Lean” companies apply tools like Kanban before they are ready. Inevitably, these companies consistently fail to achieve their desired results and soon abandon their Lean initiatives. I see it all the time.

The Toyota production system and lean thinking are not a set of tools. They are organization-wide strategies anchored in the pillars of continuous improvement and respect for people. Their sum is far greater than their individual parts.

Before any real improvements can be made, companies need to create and maintain stability—processes that are capable of delivering consistent value everyday. Since the majority of work processes are inundated with waste, companies seeking stability must first focus on getting all of their team members involved with identifying waste and using scientific thinking to eliminate it.

For this to work, it’s critical that these employees are provided with both the necessary training in A3 problem solving as well as a transparent improvement idea suggestion system that triggers and rewards action. Daily huddles with visual boards are also recommended.

Waste elimination enables continuous flow, which helps ensure value is delivered to the customer. It’s when continuous flow is impossible that pull techniques like kanban provide value. Start with the basics. Then use tools like Kanban when appropriate. Go slow so you can go fast. Continuously improve to accelerate growth.

#leanthinking #toyotaproductionsystem #kanban