Lean By Experience

New Training Simulation Engages Employees in Lean  

Two Enterprise Minnesota consultants recently created a new lean approach that helps managers accomplish one of the biggest challenges of leaning up their operations - actually getting employees to adopt the changes quickly.

"Change, no matter how small, can draw skepticism and pushback, particularly if employees don't understand the benefits of the change," said Harry Larson and Samuel Gould, writing in the upcoming issue of Enterprise Minnesota magazine. The two long-time business growth advisors at Enterprise Minnesota said their process -- The 5S Value Stream -- enables employees "to learn by doing."

The approach combines key elements of 5S (sort, straighten, shine, standardize and sustain) along with  Value Stream Mapping and Kaizen events. "Like 5S, it organizes individual workspaces using lean principles. Like Value Stream Mapping, it takes into account both a current state and a desired future state. And like Kaizen events, it all happens in a matter of days," they said.

It works like this: employees divide into three teams, each of which undertakes specific roles that maximize production within a fictional factory. Team #1 works without utilizing any lean tools; Team #2 uses some of the tools before production; and Team #3 is exposed to the whole lean toolbox.

The two consultants say that production typically increases between 800 and 1,200 percent between the first and final simulation rounds. They report that client companies have cut lead-time in half, reduced scrap by 90 percent and realized $250,000 in bottom-line savings.

Additionally, yet more involved calculations reveal other improvements, they say. "Because each team includes a mix of people from different departments, employees develop new relationships that can result in a higher trust level and better communication between production and office employees, and a team-oriented attitude across the business."

Companies looking for ways to engage employees in lean activities can contact Enterprise Minnesota to learn more.
To contact Samuel Gould or Harry Larson, click here.

   Successes in Business Innovation - Manufacturers Show The Way

Wednesday, Nov. 14, 2012
8-11 am
US Bank
1 Meridian Crossings
Arrowhead Conference Room
Richfield, MN

Cost: Regular $119

Register Online

What to Expect: 

Come learn how successful manufacturers are growing their businesses through strategic innovative investments in processes, new products, marketing, exporting strategies and more.

Speakers:

•    Tim Keran, Owner &  President
     Western Graphics
     St. Paul
 
•    Kent Mogler, COO & Vice President
     WW Johnson Meat
     Minneapolis

Register Online Today!

Have news or events for e-trends?  Contact Sue Roe at sue.roe@enterpriseminnesota.org