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Showing posts with label Lean Management. Show all posts
Showing posts with label Lean Management. Show all posts

Wednesday, October 22, 2025

Finding Your Way When You’ve Lost Momentum on the Lean Journey


Even the most committed organizations can lose their way on the Lean journey. You may have started with strong momentum—kaizen events buzzing, visual boards filling up, and teams brimming with ideas—only to find months or years later that progress has plateaued.

This is normal. Businesses that implement Lean Thinking often face a “middle dip,” where initial wins slow down and enthusiasm fades. The key isn’t to avoid these plateaus—it’s to recognize them early, address root causes, and get back on the path to improvement.

Here are practical steps to rekindle Lean success:

1. Revisit Your “Why”

When teams forget why Lean matters, it can easily become a set of tools instead of a way of thinking.

  • Reconnect to purpose – Reaffirm the link between Lean and customer value, team well-being, and business health.
  • Tell the story again – Share wins from earlier in your Lean journey. Remind people of the problems you solved and the impact made.

Tip: Host a brief “Lean reset” meeting where leadership and frontline employees openly discuss the purpose and vision for continuous improvement.

2. Go to the Gemba (Again)

Lean thrives on observation, not assumptions.

  • Visit the place where value is created—shop floor, office, or field—and see firsthand what’s happening.
  • Listen more than you talk. Ask “why” five times before jumping to solutions.

Tip: If your leaders haven’t walked the process in the last month, schedule a Gemba walk this week. Plateaus often hide in plain sight.

3. Simplify Your Efforts

Over time, Lean can get weighed down with too many metrics, too many boards, or too many disconnected projects.

  • Focus on one or two critical goals that truly matter right now.
  • Remove busywork that doesn’t directly improve flow, quality, or customer value.

Tip: Use the principle of “stop starting, start finishing” to regain focus.

4. Reignite Small, Quick Wins

Large projects have their place, but if the team only sees long timelines and delayed results, motivation drops.

  • Encourage teams to solve small, visible problems quickly.
  • Celebrate and share even the smallest improvement.

Tip: A whiteboard or digital tracker of “quick wins” can help make momentum visible.

5. Reinvest in People Development

Skills decay if they’re not used or built upon. If Lean feels stagnant, it may be time to re-skill and inspire.

  • Offer refresher training on Lean principles and problem-solving.
  • Bring in new voices—guest speakers, cross-department exchanges, or site visits to other companies.

Tip: People who grow will help the system grow.

6. Check Leadership Engagement

Lean plateaus often mirror leadership fatigue. If leaders drift from daily engagement, so will the team.

  • Leaders should model the behavior they expect—asking questions, supporting experimentation, and removing roadblocks.
  • Recognize and support leaders at every level, not just the top.

Tip: If leadership attention has shifted away from Lean, it’s time to realign priorities.

7. Reassess Your Measures of Success

Sometimes the plateau is less about lack of progress and more about outdated metrics.

  • Are you still measuring what matters most to customers and the business?
  • Could you be missing important signals of improvement?

Tip: Review your KPIs quarterly to ensure they match your current stage of growth.

Final Thought

The Lean journey is not a straight line. It’s more like climbing a mountain with ridges, false summits, and pauses along the way. Plateaus are not failure—they’re opportunities to reset, refocus, and push forward with renewed clarity.

Lean is about learning. And when you feel lost, remember: the way forward is built by going back to the basics, engaging people, and improving—one step at a time.


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Wednesday, September 24, 2025

10 Keys for Lean Daily Management















10 Keys for Lean Daily Management: Driving Continuous Improvement

Organizations often start their lean journey with Kaizen workshops, aiming for quick wins. However, many see improvements fade over time because lean depends on people consistently applying the tools. Tools like standard work succeed only when individuals understand, care, and use them daily.

Lean daily management (LDM) focuses on creating habits and routines that embed lean principles into everyday operations. It’s not just about tools—it’s about engaging people, fostering accountability, and ensuring continuous improvement.


What is Lean Daily Management?

Daily management is a structured approach where everyone—from leaders to frontline staff—takes ownership of productivity, quality, and communication. By implementing Gemba walks, leader standard work, and visual management, organizations ensure alignment and empower teams to improve processes consistently.


10 Keys to Lean Daily Management

Key

Focus Area

Purpose / Benefit

KPIs That Matter

Metrics that drive results

Identifies bottlenecks and improvement opportunities to optimize production, quality, and cost.

Setting Standards

Clear expectations

Makes goals visible, allowing leaders to guide and correct behaviors efficiently.

Visual Displays

Transparency & alignment

Boards display KPIs, targets, and improvement ideas to keep teams informed and accountable.

Daily Huddles

Team communication

Short meetings at visual boards promote discussion, alignment, and quick updates.

Gemba Walks

On-the-floor observation

Leaders observe processes firsthand, identify problems, and support employees directly.

Problem Solving

Expose & resolve issues

Encourages the open identification and addressing of problems, fostering learning and improvement.

Coaching

Continuous guidance

Leaders mentor teams to sustain behaviors, reinforce learning, and encourage proactive improvement.

Accountability Tracking

Assignments & follow-up

Converts observations into actions and ensures completion, embedding discipline in processes.

Leader Standard Work

Structured leadership tasks

Leaders engage daily, model lean behaviors, coach teams, and remove barriers to improvement.

Everyday Communication

Frequent two-way dialogue

Maintains trust, empowers employees, and ensures information flows efficiently across the organization.


Why Lean Daily Management is Essential

  • Sustains Kaizen Workshop Gains – Ensures improvements do not fade over time.

  • Engages Leaders – Daily routines and Gemba walks keep leadership active in improvement processes.

  • Empowers Teams – Huddles and visual boards give teams ownership of their work and results.

  • Drives Continuous Improvement – Problems are addressed promptly, boosting productivity and quality.

  • Builds Organizational Culture – Encourages habits that embed lean thinking into everyday work.


How to Implement Lean Daily Management

Step

Action

Identify Key Metrics

Select KPIs that measure critical aspects of production and quality.

Define Clear Standards

Set clear expectations for each task and communicate them to the team.

Create Visual Boards

Display metrics, targets, and improvement ideas visibly.

Conduct Daily Huddles

Hold short meetings to review performance and plan next actions.

Perform Gemba Walks

Leaders observe processes and support staff on the floor.

Track Accountability

Convert observations into actionable tasks and follow up.

Coach Continuously

Encourage proactive problem-solving and mentor employees.

Review & Adjust

Leaders evaluate processes and adjust actions as needed.


Final Thoughts

The true strength of lean lies in its people, not just its tools. By applying the 10 keys of lean daily management, organizations build daily routines that drive consistent improvement. Practices like Kaizen workshops, Gemba walks, leader standard work, and clear communication foster accountability, empower teams, and cultivate a culture of continuous enhancement. Organizations embracing LDM can tackle challenges quickly, solve problems effectively, and sustain high-performance operations. Over time, daily management becomes a habit, turning short-term gains into lasting success.



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Wednesday, March 19, 2025

10 Ways to Adopt a Lean Culture Today


Building a Lean culture is not an easy task. A Lean culture starts with managers who understand and believe the implications of the system’s view and know the necessity of serving customers in order to succeed. The result of that understanding is a culture where a positive internal environment and the creation of delighted customers go together. It is a culture that naturally emphasizes continuous improvement of processes, one that results in a healthy workplace, satisfied customers, and a growing, profitable company.

The best leaders understand the present is nothing more than a platform for the envisioning of, and positioning for, the future. If you want to lead more effectively, shorten the distance between the future and present. Inspiring innovation and leading change call for more than process– they require the adoption of a cultural mindset.

Implementing Lean Thinking is a cultural change that requires leadership…because in the end it’s all about people. Here are 10 things your leadership can do right now to change the culture:

1. Define Your Vision and Values

A clear vision and values can guide your organization. A vision statement shows how your company sees itself in the future, complementing the mission and values you've developed. Your vision should describe your purpose, goals, and ideal state. Your values should reflect your principles, beliefs, and expectations. Communicating these throughout the business:

  •           Gives employees information about why and how to optimize company processes or protocols
  •           Helps employees understand the value of their specific contribution, which builds feelings of appreciation

2. Leaders Must Lead the Way

The leadership of the company has a significant influence on the company culture. For this reason, the leaders must be the ones to lead the way, open the conversation, and make examples. An important point here is that leaders in Lean manage the work, not the people. Focusing on workflow management will also create an environment of shared leadership, where everyone collectively contributes to the end result.

3. Challenge the Process

Continuous improvement encourages teams to question the status quo, seeking ways to optimize processes and minimize waste. They use Lean Thinking to look for innovative ways to improve the organization. In doing so, they experiment and take risks.

Don't miss the opportunity to identify the actions you need to improve the improve the process, while also being open to the knowledge and skills you need to develop. Challenging the process, particularly by searching for opportunities and experimenting and taking risks, is a key behavior to adopt in a Lean culture.

4. Eliminate Fear of Failure

Experiments will not always bring exceptional results. Not every new idea will be a winning move. For this reason, in a Lean culture, it is essential to show tolerance to failure. Otherwise, extreme criticism can create fear in your people and block experimentation.

A Lean culture is a learning culture, so it is of great importance to extract learnings from failures as much as from successes. Promote small-batch testing to minimize potentially harmful results from unsuccessful experiments. Also, as a company leader, make sure to speak openly about your failures and the learnings from them to give an example of how they should be analyzed and built on.

5. Empower Employees

Empowering employees is a key aspect of a Lean culture. This means giving employees the authority and resources they need to make decisions and improve processes. By empowering employees, organizations can tap into their knowledge and experience and create a culture of continuous improvement. This can be achieved by providing training, coaching, and support, and by creating a culture of collaboration and teamwork.

6. Train Employees

Training in Lean is essential for employees to understand how they are expected to work in the new culture. This cannot be a one-off activity though. Ensure they are taught specific Lean philosophies and Lean tools and supplement this with periodic training to help them stay current with the latest developments in Lean methodology. Leaders can go a long way to reinforce training by talking to employees about the training they have attended and how it has enabled them to be better practitioners of Lean.

7, Foster a Learning Environment

Continuous improvement depends upon employees learning and choosing to optimize their performance. In a Lean culture, company leaders help every employee continually learn new skills and advance their careers. This commitment to development usually encourages employees to be proactive about continually improving organizational processes. Strategies for fostering an environment of continuous learning and improvement include:

  •  Developing internal training opportunities, such as courses or job shadowing
  •  Sending employees to industry conventions, workshops, or conferences
  •  Providing ways for employees to make suggestions about their department or the company
  •  Soliciting anonymous feedback about aspects of the organization

8. Make Change Everyone’s Responsibility

Continuous improvement requires the participation of everyone in the organization. This includes the executive suite, management, and line workers. The continuous improvement program becomes effective when employees are engaged in developing the culture and are proactive in identifying areas for improvement. To do this, everyone should understand their role and contribution to the company’s continuous improvement program. Only by “rowing” together can the goals of the improvement program be achieved. Part of working together on this effort is sharing the responsibility of the program across the entire organization.

9. Create New Habits

Creating a continuous improvement culture requires changing people’s habits. Habits are the set of things that people do subconsciously on a daily basis. They are in fact very difficult to change. Part of the challenge of starting and sustaining a continuous improvement program is identifying a set of desired behaviors and continuously reinforce them. This can include training and retraining employees, helping people understand when their behaviors are misaligned with the continuous improvement efforts, and giving positive feedback to those who exemplifies the desired behaviors.

10. Celebrate success

Continuous improvement is hard. It requires employees to critically think about their work and examine potential ways of improving it. As your continuous improvement program begin to gain more momentum it is important to remember the people who make it possible. One way of sustaining the process is to regularly share success stories and recognize those involved. Many employees take pride in their work and are intrinsically motivated to improve them. They are simply looking for recognition and praise for a job well done.

Constant change is a business reality, and organizations must continually adapt to their environments to stay competitive or risk losing relevance and becoming obsolete. For each change, leaders must define it, create a vision of the post-change world, and mobilize their teams to make it.

Fundamentally, a change of culture occurs when people start behaving differently as a result of a change in the climate of the organization. There are many different models of how an organizational culture is shaped by the prevailing climate and how it can be assessed.

Leaders who protect the status quo through control must surrender to change in order to secure the future for their organization. Don’t be the leader who rewards herd mentality, and me too thinking. Don’t be the leader who encourages people not to fail or not to take risks. Be the leader who both models and gives permission to do the exact opposite of the aforementioned – be a leader who leads.

Lean success requires a change in mindset and behavior among leadership, and then gradually throughout the organization. So it follows that success in Lean implies a change in what leaders reinforce—a change in leadership behaviors and practices. Change begins when leaders start acting differently. It’s that simple (but not that easy).


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Wednesday, February 19, 2025

Foster a Culture of Accountability in a Lean Organization



Lean leadership emphasizes a culture of accountability where individuals and teams are empowered to take ownership of their actions and outcomes. This fosters a continuous improvement mindset within the organization, driving efficiency and effectiveness.

Lean management is a leadership approach that supports continuous improvement through collaborative problem solving. Rather than leading from the top down, Lean managers strive to actively engage their teams in the improvement process in order to promote personal and organizational success.

The basic components of Lean management are:

  • Standard work (SW). Tasks are broken into a series of steps that are followed by all team members. Standard work is continuously adjusted to decrease waste and add value until a state of perfection is reached.
  • Visual controls. Team members have an opportunity to track their own performance in real time and adjust.
  • Daily accountability process. The group comes together to review progress, refine processes and chart next steps.

Daily accountability throughout the organization, especially at the leadership levels, is the key to sustained transformation. Here are four reasons why accountability is so important to Lean management.

Accountability Builds Trust

Perhaps the most important result of accountability is trust, which is essential in any relationship.  Being accountable to something means that you’re willing to make commitments and be responsible for your own actions. This promotes trust between you and the people around you. When you allow yourself to be accountable to this trust, you’re effectively telling people that you’re going to admit it and make amends when the trust is broken.  In effect, you’re emphasizing how important and committed you are to the strategy.

Accountability Improves Performance

Accountability eliminates the time and effort you spend on distracting activities and other unproductive behavior. Research shows that some people have the tendency to engage in ineffective behavior. Without accountability, you may only catch these behaviors when mistakes and errors have already been made and your organization has already suffered the loss. By building a culture of accountability on the onset, you rid your organization of ineffective behavior, put the right people on the right jobs, and send the message that you’re serious about excellent work.

Accountability Promotes Ownership

When you make people accountable for their actions, you’re effectively teaching them to value their work.  Through positive feedback and corrective actions, they learn that their behavior and actions have an impact on the team. They’re not just floating members without clear roles to play – they’re important to your organization. When people know that they’re valued and important, they’re more driven to work hard. They learn to have a sense of ownership in what they do.

Accountability Inspires Confidence

When done right, accountability can increase your team members’ skills and confidence. Don’t mistake accountability for controlling behavior. The key is to provide the right support – give constructive feedback, improve on your members’ suggestions, give them freedom to decide, and challenge them to think of better solutions as a team.  When people know that you’re listening and concerned about their performance, they’re more likely to step up and do their best.

Given these reasons, it’s important that you build a culture of accountability from the start.  Remember that accountability is building a culture of trust and not fear.  Your goal is not to punish and look for errors and mistakes. Instead, you seek to open multiple feedback mechanisms, fill in gaps, improve on solutions, reward productive behavior, and remove unproductive ones. As a leader, you yourself should hold yourself to the highest level of accountability.


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Monday, February 10, 2025

7 Steps for Leading Lean

Embarking on the journey of Lean is akin to setting sail into a vast ocean of continuous improvement and relentless pursuit of excellence. It’s a voyage that demands not only a steadfast commitment to the principles of Lean but also an unwavering dedication to fostering a culture of empowerment and respect within an organization. Lean leadership is not merely about streamlining processes and eliminating waste; it's about nurturing a mindset that embraces change, values employee contributions, and continuously seeks ways to enhance value for the customer.

Leadership commitment and support is critical for successful process improvement initiatives. Fortunately, it is not particularly complicated to make a difference. Here are seven steps that leaders can take to support Lean process improvement efforts.

1. Set Goals

Create a vision of the future state and determine where to focus your efforts. Lean is often surmised as doing the right things at the right time and cost. Set concrete goals with a time frame for when you want to achieve those goals.

2. Get Started

Successful leaders start immediately. They don’t drag their feet or put it off. They act on a goal right away, because they understand the power of momentum. They may not do the whole thing at once, but they do take a big step to get started. There is never a better time than now to get started.

3. Think Positive

This is the half-empty, half-full syndrome. Lean leader are optimists and believe the cup is always half full. They aren’t pie-in-the-sky types, but they see the positive side of an opportunity, and they believe in their ability to achieve their goals.

4. Take Action

Those who are successful take action, even on partial information. Too many people wait around until they think they have all the answers. But if you do that, you may wait forever. Lean leaders don’t proceed blindly, but they know that, once they have the critical details, they can make a decision and act accordingly.

5. Be Determined

Implementing Lean is no easy endeavor. There are so many variables that it is impossible to determine how things will proceed. You don’t know what will happen once you take the first step, so the only constants are the end vision and your determination to get there, even if the path doesn't unfold exactly as you envisioned.

6. Lead by Example

You must hold yourself accountable before you can hold anyone else. A leader implies followers are doing just that, following. If you want to be a leader, you must go to the source and see the actual condition from those that make it happen. It is from the Gemba that you have the best opportunity to coach improvement.

7. Learn From Your Mistakes

To be a good leader you have to take calculated risks, and you will certainly make some mistakes along the way. Admit them. Learn from them. Don't repeat them! Mistakes are a necessary part of the learning process.

Being a good leader may sound simple, but it is not easy. It requires tremendous strength of character. Almost all successful leaders will tell you that being extremely focused on the outcomes they wanted to create, trying many different approaches to achieving them, and staying the course all add up to success.

The journey of Lean leadership is one of transformation, both personal and organizational. It's a path that requires patience, humility, and a genuine desire to serve others. By embodying these principles and practices, leaders can guide their teams to achieve remarkable results and create an enduring legacy of excellence.


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