Common, everyday problems do not go away once a company has successfully adopted lean. Daily problem solving must still occur in order to sustain a lean operation. Here are some tips, compiled by Bosch Rexroth, for solving daily problems. These tips aim to help organizations sustain improvements achieved with lean implementations and prevent backsliding.
Six daily problem solving tips:
- Keep what may seem like little problems from adding up and becoming big problems in the future. The only way to work on tomorrow’s problems is to work on the problems today while they are still small.
- Use visual management and standard work tools to catch problems before they start adding up.
- Build the skills, tools, and systems needed to deal with those problems as soon as possible.
- Start using the “5 Whys.” Continue asking “Why?” at different stages in order to dig deeper into the root cause of a problem.
- Use Plan-Do-Check-Act (PDCA). Without fully understanding the cause of what is happening in a situation, an organization will not have the control in its processes needed to sustain lean.
- Understand that the small problems are a valuable contribution for future results.
“Daily Problem Solving in a Lean Organization” is available as episode #6 in Rexroth’s lean manufacturing podcast series, available for listening or free download from the company’s website at www.boschrexroth-us.com/leanpodcast. The podcast series is also available from the iTunes podcast library and other podcast directories on the web. Developed by Bosch Rexroth’s Linear Motion and Assembly Technologies group, each 8-10 minute lean manufacturing podcast episode presents guest experts and information to help manufacturers and OEMs understand and apply lean principles and practices in their businesses.
Developed with lean manufacturing expert Jamie Flinchbaugh, “Daily Problem Solving in a Lean Organization” can help businesses sustain the improvements they’ve made, and deepen their commitment to lean.
Flinchbaugh, who is co-founder of the Lean Learning Center and co-author of the popular book The Hitchhiker’s Guide to Lean, emphasizes that lean manufacturing is a process and a culture, and not simply a project. Continuous improvement is needed to sustain a lean operation.