After Learning Six Sigma, Lean was next on my list. So, when I read details about this book on social media, its fascinating title, and the fact that this book also discussed about RMAOR approach to implementing Lean in an organization, I decided that had to read this book. This book was my introduction to the subject of Lean.
Best part that I liked about the book is it’s highly structured & organized content. Author has written the book in a simple & easy to understand language. The book starts with Why adopt Lean followed by how Continuous Improvement (CI) & Quality Philosophy evolved. It also introduces the readers to Lean Thinking & Evolution of Lean. There is also a chapter dedicated on Myths of Lean.
In part 2 of the book, the author proposes a new methodology for lean application called RMAOR (Recognise - Map & Measure - Analyze - Optimize - Repeat) with step by step roadmap and tools and techniques that can be applied. Six Sigma makes use of the DMAIC problem-solving framework, but Lean does not. Hence RMAOR approach is proposed by the author.
By reading this book, it helped gain clarity on concept of Lean and how it is different from Six Sigma.
The key learnings from the book that I want to share with you are:
- Lean is a strategy for reengineering an entire organization for breakthrough improvements. In many cases, lean interventions are performed with tools, but there are no ways to do things or beliefs, which is why organizations don't see any lasting results. A lean approach is more than a tool; it is a philosophy that is applied through methods and tools to accomplish a company's financial goals.
- Implementing 5S, Kaizen, and TPM on the shop floor may serve as a good starting point to enroll and involve people in continuous improvement culture, but may not have any breakthrough effects. Only when Lean is applied as a top-down organizational strategy to gain a formidable competitive position does it enhance profitability and growth.
- Six Sigma minimizes variation and defects, while Lean improves manufacturing/service efficiency. Many organizations solve a single problem at a time with one tool, like six sigma. Such approaches do not last long and yields only marginal improvements.
- The main challenges in implementing Lean are cultural changes rather than technical ones. During the transformation process, leaders and change agents must ask, “What are the expected outcomes?” as well as “Why is the transformation necessary?” before taking action to transform the organization. The choice of the ideology, methodology and tools should follow, after answering the above-mentioned questions.
In my opinion, the book offers a comprehensive understanding of Lean and is a great way to learn more about it and thus gain new skills.
