Lean Organisation

Why is it important?

Based on 20 years experience, working with clients, implementing Lean/Operational Excellence, Organisational Maturity, excell in the transformation and sustaining/continued improving of the subsequent performance. Organisational Maturity, defined as Vision, Mission and Values driven, rigorous Policy Deployment , well structured eg Span of Control (1:3:7), with standardised processes and clear Roles and Responsibilities, promoting employee performance, productivity and engagement (Respect!). This results in the elusive 'high-performance culture'

Our experience

Our industry experts and coaches have decades of experience structuring, enhancing and developing organisational and cultural behaviours in companies of different scales. From Metals & Mining to FMCG, Pharmaceutical to Aviation, Lean Coaching has always proven to be a strong partner to our clients in culture and behaviour improvement. Typically working with leadership and change agents of companies and applying Toyota Production System (TPS) approach, our goal is to make sure the change and capability to support it stays within the business and keeps growing together with maturity levels of our clients. ​

Lean / Operational Excellence Change Agent development

What is it?

Typically a 1 year program where every day of a future Lean expert is filled with on-the-job activities, shopfloor coaching, learning (70-20-10), workshops, cross-functional collaboration around real life issues (supply chain, quality, production, logistics, etc.). During the program the experts are continuously assessed and coached by experienced practioner-trainers

Why is it important?

Having Change Agents at all levels ie Lean Specialists, Experts and Coaches in a critical mass (ca 1% of FTE) is crucial for Business Transformation ie Ensure sustainability​, Create a learning organization​, drive problem solving and continuous improvement, not to mention, the organisation having a talent pool of demonstarbly capable future managers​

Key Elements/Terms

- Change agent development
- Skill levels
- Multiskilling
- Upskilling
- Competency assessment
- Leadership skills
- Functional skills
- Soft skills
- PDP (personal development plan)
- 1-2-1 coaching
- Check-in

Lean Operator training

What is it?

Training package and Yellow/Green Belt Certification, designed to be changed according to a particular client’s needs (both short and long term). Our Coaches diagnose the gaps between actual and required competency and provide training topics, tailored approach (theory + benchmarking + real business issues to solve during and/or after the training), initially delivered by LC but always with a view to Train Trainers and transfer know-how

Why is it important?

Employees are your most valuable asset. Operators are the ones that create/add direct value and are responsible for thier safety and the quality of the product. They know where the real losses and any potential dangers are. All of the above makes them the most important allies for business improvement and loss reduction, through problem solving and continuous improvement.

Key Elements/Terms

- Lean history, Lean Thinking
- Stability, Flow, Takt, Pull
- 8 types of waste, 5S
- Standard Work, Visual Management
- PDCA and A3 problemsolving
- Kaizen, Focused improvement

Lean Leadership​​ Coaching

What is it?

Coaching of leadership involves assessing their behavior and style, evaluated in the daily execution of their current role. Criteria include multiple dimensions of Knowledge, observed bevaviours and processes used. These are compared with Lean/Op Ex best practice, adapted to specific local requirements and an overall Action Plan and Personal Development Plans (PDP) are agreed. Coaching by experienced practioners allows each Coachee to benefit from this experience.

Why is it important?

This Sensei Coaching approach, by Toyota's own admition, is the most critical factor in their approach to building and deploying TPS so succesfully. It seems more time consuming for future managers to coach rather than just tell - but the capability building and motivational impacts, making both more sustainable, means less repeat training/instruction (resources/effort) in the longer term.

Key Elements/Terms

- 1-2-1 coaching
- '1 Minute Manager'
- Mentor- Mentee/Coach-Coachee
- Gemba Go and See
- Situational Leadership
- Model Behaviour
- Personal Development Plans (PDP)

Organizational Maturity​

What is it?

Organisational Maturity involves aligning Organisational Structure (Teams with Team Leaders - Span of Control), Organisational Capability (Members, Change Agents and Leadership) with Lean Processes (Std Work, TPM, JIT - Hoshin Kanri, Shop Floor Management, Problemsolving and CI - .. to drive Performance now and in the Long Term

Why is it important?

Many failed attempts to reap the benefits of Lean/ Op Ex transformations have failed due to either
1) copy pasting tools, methods and systems - instead of these being 'pulled' as countermeasures to real problems from KPIs or strategic objectives
or 2) only implementing some aspects in some areas and stagnating - as opposed to letting it grow organically as fast and far as the organisational capability can follow (PxC=R)

Key Elements/Terms

- Sisyphus pushing the Stone
- Holistic Sustainable Transformation
- Culture Change is a result, not the starting point