12 SUCCESS FACTORS OF

LEAN PRODUCTION

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 The 12 Success Factors of any Lean Implementation
Create AWARENESS for
01 lean activities inside your
organization (Top down!).
MANDATORY for any lean approach:
You need the support of your top
management. Use trainings and good
lean examples to convince key players.
CONSEQUENTLY
08 Implement a 2-box
principle.
Switch all parts to SMALL
09 BOXES with low quantities
to increase flexibility.
Use small-sized boxes and the 2-box
principle to implement a highly flexible
PULL in your factory.
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Create DISCIPLINE and
02 the sense for standard
routines.
Convince your production leaders and
managers to form the foundation for
all lean activities: Shop floor
DISCIPLINE.
Use the 1 operator as
07 the Mizusumashi to
SUPPORT the line.
Implement the operator as the water
spider to supply your line with material
based on a high delivery FREQUENCY.
10 ELIMINATE any
changeover time at all.
Follow the SMED approach of
separating internal and external
changeover processes. Eliminate any
internal changeover at all.
Start 5S activities and Define ONE PILOT LINE to
03 create a mindset. Form a
LEAN CULTURE!
04 start with. Use a stable
but important line.
Define people responsible for 5S
audits and routines. Create 5S sheets
to measure your progress.
BALANCE the assembly
PRECISELY CALCULATE
06 line according to that
takt time to gain 1 05 the takt time for that
line.
operator.
Use the Yamazumi chart to balance the So many companies fail to tell you the
pilot line to the calculated takt time. necessary takt time. Make sure to be
Reduce the numbers of operators to very accurate on this matter.
gain 1 operator for free.
IMPLEMENT mixed SUSTAIN and MAINTAIN
11 model lines with zero
changeover time.
12 all activities with 5S and
TPM
Produce your products with low batch- Make sure to define standards once
sizes. Perform many changeovers to you do modifications and
level your production and eliminate the improvements. Use TPM to further
BULLWHIP EFFECT in your supply increase productivity.
chain.
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