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Lean manufacturing processes have revolutionized the way that many leading enterprises
deliver products to their customers and manage their supplier relationships. Over the past
few years, the use of Lean techniques has expanded well beyond the automotive industry
to delivering dramatic results into other sectors including aerospace, consumer goods,
and industrial equipment among others. Although C-level executives are enthusiastic
about the benefits that can be derived by "Leaning out" operations, this study uncovered
a large performance gap between those companies that are simply using Lean techniques
on the shop floor versus those that have built a culture based on Lean thinking.
Key Business Value Findings
Of the close to 300 manufacturers that participated in this study, 90% reported that they
are committed to Lean. However, further analysis found that less than 20% of these
companies can be considered best-in-class. Companies that have achieved operational
excellence through the deployment of a Lean strategy share three key characteristics:
- Dedication to basics such as streamlining processes, creating a well ordered
work environment, and ongoing continuous improvement programs (Kaizen).
- Lean processes have been rationalized and streamlined; Lean techniques have
been memorialized and a ‘single version of the truth’ is ubiquitous via a technology
infrastructure that supports manufacturing, the enterprise, and the supplier
base.
- Lean principles are reflected in the corporate strategy, on the senior leadership
team, as well as throughout manufacturing and the company.
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