Implementing Lean and Six Sigma can be challenging for many companies. Often the first process improvements are relatively easy, and this can create the impression that implementing Lean and Six Sigma is effortless. However, long-term commitment and continuous improvement are required to achieve the full potential.
Here are a few ideas if progress starts to stall:
1. Resistance
Staff may be hesitant about change, old ways of working may be deeply entrenched and there may be a fear of change.
Ideas for solutions:
- Behind resistance there is usually a fear of something, for example, fear of incompetence, fear of losing a job, fear of endurance, or fear of losing one's position. Find out what fears are behind the reasons for resistance. Once the cause of fear is identified, it is easier to consider solutions, such as training to help with the fear of incompetence and involvement to address the fear of losing one's position.
- Take small, fast-track projects and select the most enthusiastic people to get good examples of results quickly and get the momentum to start new projects.
2. Objectives, measurement and monitoring
Setting, measuring and monitoring targets at all levels of the organisation is important so that staff understand why changes are needed. Organisations may lack concreteness of objectives, measurement systems and data collection.
Solution ideas:
- You can even start with just one meter and upgrade as you gain experience. Reducing lead times is often a good way to start. A single metric can improve many things: it speeds up the process by reducing waste (mess), which in turn has a positive impact on customer and employee satisfaction and costs.
- If measuring is difficult in your organisation, at a minimum you can certainly measure the amount of waste and set a target of halving it.
- Ensure management support for the objectives and set targets that are challenging enough to get the organisation moving. A 50-90% improvement target will "force" you to think about effective elimination of waste, while a 10% improvement will be achieved by "running" the process through faster, making the situation even worse.
3. Lean training
Organisations may lack the necessary skills. Lean and Six Sigma require specific training.
Solution ideas:
- Select key people for training and make sure they have enough time.
- Choose training that focuses on the essentials and doesn't overload you with unnecessary tools.
- Make sure the trainer can adapt the examples and exercises to your organisation's needs.
4. Communication
Poor communication can cause challenges in implementing Lean and Six Sigma. Staff need clear guidance and information on the progress of change.
Solution ideas:
- Create an open and regular communication channel to share information and explain the progress of changes. Keep the issue on the agenda at key events.
- Organise workshops and provide channels for employees to express their opinions and concerns.
- Also take into account interrupted projects in communication, these are also important.
5. Ongoing commitment
Lean and Six Sigma are not individual projects, but continuous improvement. The challenge is to keep the organisation committed to continuous process improvement.
Solution ideas:
- Organise regular monitoring and evaluation to maintain commitment. Mobilise management to be involved in events.
- Encourage and reward continuous improvement. If you find it difficult to come up with incentives, ask employees what motivates them and what gets on their nerves in their working environment.
- Try to periodically blow a fresh wind into the approach if you get numb.
6. One last tip if you're running low on energy
If you run projects, workshops, trainings, etc., you should be enthusiastic and inspiring to get people involved. Enthusiasm doesn't always come naturally and energy levels are low.
Solution ideas:
- This is a tip I got from my coach who was approaching retirement when, as a young trainer, I was amazed at his endless enthusiasm: "Always try to do something in a new way and you'll stay sharp." Change the introductory exercise in a workshop or brainstorm with a different technique. It doesn't have to be a big change, even a small change will help you stay sharp and keep your enthusiasm and energy levels high.
- Remember to smile and at least try to look enthusiastic.
I hope these gave you ideas and energy to continue using Lean in a productive way.
You can read more about this in my previous blog: Lean Leadership: 6 factors to achieve more results
If you want to get some more insights into Lean Leadership, please check out the Master Lean Leadership training.
Please contact us if you have any questions.
Lean Six Sigma,
Certified Lean Six Sigma Master Black Belt
