Lean Manufacturing
offers a big step for-ward. Lean is a system that can beat mass pro-duction systems. It does this by minimizingwaste.Most organizations that “go Lean” try to do soby implementing Lean practices on the factoryfloor only. That is good and well, but thesecompanies miss three important points:•Lean relies on
everyone
in the organizationcontributing ideas for improvements, andtaking responsibility for implementing. This ispossible only if management makes a delib-erate shift from Theory X to Theory Y.•Lean is not a mass production system. CostAccounting is not a valid accounting systemwhen using Lean. Companies that go Lean
must
replace Cost Accounting with an ac-counting model better adapted to Lean prin-ciples. For example, overhead allocation andcounting inventory as assets are not accept-able in Lean organizations, because it under-mines the ability to make correct decisions.•Strategy concerns everyone with manage-ment responsibilities in a Lean company. De-cisions are made at the top, but the entireorganization is involved in providing top man-agement with information before decisions aremade. After a strategy has been set, a formaldeployment method,
Hoshin Kanri
, is used todeploy the strategy throughout the companyand ensure that everyone knows what rolethey play in implementing the strategy.Lean provides managers with a range of optionsfor reducing
investment
(including inventory). Thisfrees up capital, and can improve an organiza-tions financial health without cost cutting. Part of the Lean philosophy is to ensure that a companynever has excessive costs in the first place.Lean emphasizes Management By Means (MBM),that is, focusing on process and process im-provement, rather than Management By Results(MBR) which is the most common method to-day. MBM is a great step forward because it en-ables managers and employees to be proactive,and actually do something to improve their ownsituation, and that of their company.Lean uses a hierarchical organization, and thefocus is on internal improvement. Lean is power-ful, but still leaves many possibilities untapped.
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Profitsshrink!LeanRespect forpeopleAutonomationLeanAccountingKaizenSevenWastesFive WhyPoka YokeKaikakuHoshin Kanri(StrategyDeployment)ReduceInventory
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