The client had “tried lean before” with some initial success but eventually returned to the old way. As a result, lean had developed a bad name, with some staff openly hostile towards it.
Efficiency Works was engaged to reinvigorate and revive the lean initiative.
Efficiency Works executed a three-phased approach to turn the culture and the business around, address misconceptions, and embed lean as a part of everyday work.
Step 1 Strategy program aimed to:
- Establish what the business needed to do in order to be successful
- Help the leadership team crystallise the challenge
Step 2 Learner programs:
- Provided high level education on what lean is and is not\
- Were delivered for influential staff via Certificate IV in Competitive Systems and Practices, a formal training course requiring a year to complete
Step 3 – Blitz Program:
Restored faith in the improvement program using 5S and setup reduction techniques
The phased program approach assisted the company to achieve:
- a strategy where there was very little before, coupled with an understanding of that strategy throughout the business
- significant and quick improvement in 5S and setup times thanks to the blitzes
- sustained improvement because of the long term commitment to the learner program
- leaders and teams focused on improvement rather than just plodding along until the next fad comes along