10 Steps to Become a Lean Enterprise

An Introduction to the 10 Step Lean Training and Implementation Model

The 10 Steps to become a Lean Enterprise training and implementation model was created and developed by Chris Turner – Lean Mfg Coach. It is the result of 30+ years of hands-on experience working with clients and sharing in their desires and frustrations when it came to learning and trying to implement lean principles into their own organizations. Chris Turner developed the model in the 1990’s after doing his own research to try to find  the key to all successful lean implementation projects. He wanted to understand why some improvement teams achieved incredible results, while on the other hand, so many failed. What he found during his research really surprised him because the findings were not what he expected. He discovered a reoccurring pattern in the way the successful teams were trained about the application of lean manufacturing principles.

Chris Turner found that the improvement teams from the most successful projects were only trained in a limited number of lean tools and techniques. In fact, he discovered there was an average of eleven different lean tools and techniques being utilized. This was a big surprise, because there are literally hundreds, if not thousands of different improvement tools and techniques that are being used by companies throughout the world.

So, this caused him to think and ask a question. “Was it really this easy? An average of eleven tools, that’s all.”

Chris had to be sure, so he decided to formalize his research and went on to designed and developed the ’10 Steps to become a Lean Enterprise’ training and implementation model. The list of lean tools and techniques included in the 10 step model are taken from the Toyota Production System (TPS). As most people know, Toyota is accepted as a benchmark to a world class lean enterprise. The 10 Step training and implementation model follows a natural progression in growing organic capability and creating a successful process improvement infrastructure. This goal is to create a road map to guide an organization through their lean implementation process. The 10 Step training and implementation model adheres to the principles of Plan, Do Check, and Act – PDCA (or Deming) Cycle. In the ‘DO’ section of the model the steps are divided into two categories of activities: in the left hand column is Process Control and in the right hand column is Process Velocity. These central column separates after Step 2 – Value Stream Mapping, then the left and right columns converge at Step 8 – Standard Work

10 Steps Lean Training and Implementation Model

Here are the ten steps from the 10 Steps to become a Lean Enterprise training and implementation model:
10 Steps to Become a Lean Enterprise

Step 1 – Strategy Deployment
Step 2 – Value Stream Mapping
Step 3 – Workplace Organization
Step 4 – Improve Process Flow
Step 5 – Reduce Changeovers
Step 6 – Implement a Pull System
Step 7 – Balance the Workload
Step 8 – Standard Work
Step 9 – Continuous Improvement
Step 10 – Lean Supply Chain

 

The ten steps are in a specific order, but an organization must only implement steps 1, 2 and 3 in the prescribed sequence. Steps 4 through 9 can be done as and when the resources or opportunities become available.

The 10 Step lean training and implementation model takes and individual or group through three levels of application proficiency and capability.

These three levels are:

Level 1 – Lean Awareness
This is our beginner level training package.
Level 2 – Lean Practitioner
This is our intermediate level training package.
Level 3 – Lean Expert
This is our advanced level lean training package.
The 10 Step lean training and implementation model can be applied to any business, organization or process.

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