Many organizations embark in a Lean journey often not realizing the road ahead. Studies have shown that many organizations start but relatively few accomplish their objectives when initiating a Lean transformation. Leaders should realize that starting a Lean transformation cannot be taken lightly. Depending on where the organization is in their journey, a Lean transformation may require significant change. Business leaders should be prepared for, among many things, the following:
How long will it take? – There is no pre-determined length of time to complete a Lean transformation. Every company is a distinct scenario. There might be two companies, from the same industry, that go through a transformation; what you will find is that the process, the time, and the results may be completely different.
False starts – Many companies go through what I call a false start of a Lean implementation. Typically, these are initiatives that fail and employees begin to call it a fad. There may have been some early wins but momentum has been lost completely. The dangerous part about this is that organizations may lose the ground made and even worse leaders may lose the credibility of their workforce.
Some people might not make it – During a Lean transformation people go through certain transitions where behaviors change and new habits are formed. This creates an environment where current practices are constantly challenged. There are cases where some individuals resist change to the point where they rather leave than change.
Bullets vs cannon balls – As a Lean transformation progresses, the impact of process improvements is reduced. The “low hanging fruit” begins to run out and your team is making more challenging improvements. Some organizations expect the initial dramatic improvements to continue through time; As you make more improvements those large cannon ball improvements will turn into small bullets, still impactful just in a smaller scale.
Stressful – An organization may develop a strong opinion against initiating change. People are creatures of habit and situations may become stressful for many reasons: Fear of job loss, fear of change, etc.
Fun – As your organization begins to embrace change, people will begin to realize the benefits of improvement. Many will get joy out of taking something that was not working and creating a more productive outcome.
Better Performance – There will absolutely be bottom line impact to your organization. Better quality, faster lead times, increased capacity, among other benefits.
Improved work environment – Even though hard to quantify, the work environment will improve. Where there was conflict, you will see collaboration. Instead of complaining about problems, people will instead take ownership and begin looking for ways to eliminate the cause.
My intention is to make leaders aware of some things that may not be obvious before starting this journey. Below are some suggestions I can offer that can help make your experience more productive: