Page 87 - Lean six sigma demystified

66 Lean Six Sigma DemystifieD

The Mind Learns in Color

The human eye can readily detect color. Once your mind gets used to seeing a
certain color associated with a certain tool, product, or process, the two become
linked in your mind. So, when you see the right product (e.g., tube) with the
wrong color or the right color in the wrong place, it sets off an alarm in your
mind that will help prevent a mistake.
Work in technicolor! Still trapped in black-and-white thinking or just shades
of gray? How can you start using color to mistake-proof your processes?

Get Started Immediately

Reorganize your company by product family and value stream. Topple the
silos and implement the flow. Move the machines and people into prod-
uct cells immediately. Reduce the number of suppliers. Help your remain-
ing suppliers implement Lean. Downsize the laggards. Two steps forward
and one step back, is okay. Devise a growth strategy. Kaizen (i.e., improve)
each value stream multiple times. Teach Lean thinking and Lean Six
Sigma skills to each pilot project team as you go. Right-size your machines
and tools.
You should be able to create a positive cash flow from applying Lean in less
than 90 days and become best in class in just 24 months. It doesn’t take that
long to get results with Lean. It does take a series of iterations to squeeze out
all of the non-value-added delay, waste, and rework and to align your business
to the principles of Lean.

How Do I Get Started?

First, you will need to create a crisis. This is easy during a recession; everyone
needs to simplify, streamline, and optimize operations to maintain a positive
cash flow. The most difficult step is the first one. You will need a change agent,
a crisis in a mission critical process (externally or internally generated), and a
determination to get results quickly. Then you’ll need the determination to
keep going. Leaders and employees who thrive on change and continuous
improvement are often in short supply.
Demand immediate results. Pick a pilot area that’s open to change and jump
right in. Line up the machines and work steps. Eliminate delays. Slash the
inventories. Dramatic reductions in lead times, inventories, space, and defects
should be possible in weeks not months.