Real Lean Manufacturing vs Fake Lean Manufacturing
This video explains the key differences between real Lean manufacturing and fake Lean manufacturing, and how to avoid the traps of using Lean tools without solving real business issues, creating an appearance without substance, or falling into the trap of training without practice or following standard work.
Additional Resources
📚 Better Thinking, Better Results - Bob Emiliani
https://amzn.to/40xMO8r
📚 Real vs Fake Lean - Blog Post
https://bobemiliani.com/back-story-re...
▶ Bob Emliani on Linkedin
/ bob-emiliani-660a72170
🗨 Dan Davis Interview on fake lean manufacturing
https://www.linkedin.com/feed/update/...
✏️ Here is the summary of the video
I've been reading an interesting book that highlights the difference between Real Lean and Fake Lean.
Real Lean involves a management system that consistently embraces the entire organization based on two principles, continuous improvement, and respect for people.
Fake Lean, on the other hand, only focuses on continuous improvement as a set of tools to fix metrics.
The book that inspired this video is "Better Thinking Better Results" by Bob Emiliani, which provides a detailed account of the Lean transformation of Wiremold under Art Byrne.
The book also has a chapter on Fake Lean, which explains how to recognize it when Lean principles are only used in operations and not throughout the company.
▶ 9 Symptoms of Fake Lean
Dan Davis provides nine symptoms of Fake Lean in his posts and interviews to watch out for. Check out the links in the description for further reading.
1️⃣ Tools to use the tools
Using Lean tools without solving business issues can be a dangerous trap.
2️⃣ Appearance without information
Real Lean focuses on the culture shift, understanding the why, and having pride in the company by serving the customer with a continuous improvement mindset.
3️⃣ Boards with stale information
Metric boards should be easy to read, and everyone should understand why the metric is being tracked.
4️⃣ Training without practice
Lean is a hands-on sport that requires practice and the creation of "playgrounds" or "sandboxes" that allow people to test new concepts.
5️⃣ Complicated metrics board
Metric boards should be easy to read and understand, with a clear target and actions to be taken when a miss occurs.
6️⃣ Kaizen without maintenance
Kaizens should take the process to the next level to better serve the customer, and improvements need to be maintained like cars.
7️⃣ Unfollowed standard work
Standard work is critical to Lean, and it should include takt time, standard work sequence, and standard work-in-process.
8️⃣Visuals without meanings
Visual management should have an intent and purpose, and not all visuals can be copy/pasted.
9️⃣ Change without culture
Change for the sake of changing can be a dangerous trap, and it is important to address the culture when making the change.
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