3. A Great List of Common Lean Myths

1. Implementing Lean results in eliminating workers.
False. Implementing a Lean culture will actually require more participation from employees because their input will be more heavily sought.  Consider this: if a company eliminates workers after they have given their input and improved a process, how much do we really expect their remaining peers to provide feedback of their own?

2. A Lean environment requires everybody to work harder.
False. The focus of a Lean production system is to change the way work is completed so that an team member's job become not only more efficient, but also easier.

3. Lean is just "kanban" or "time studies" "JIT" "Kaizen" "TQM in a different package", etc…
False.The body of knowledge that we call Lean Manufacturing today is broad and diverse.  In any case, if becoming Lean were as simple as repackaging the tools of TQM, wouldn't all manufactures be incredibly efficient and world-class?

4. Lean means operating without any buffers or safety stock.
False. Every company needs buffers, but they must be well planned and controlled. As anybody who has spent some time in a manufacturing plant will tell you, operating without buffers is a sure recipe for a rough day.

5. Lean means cranking up all the machines to get more product out the door.
False. In fact, in some cases Lean teaches us to stop machines if they are producing unneeded inventory. Remember the worst waste of all: OVERPRODUCTION

6. Lean is just a bunch of Americanized Japanese words.
False. Words alone can not make changes on the shop floor.  For that we need action. And action requires people.

7. Lean is just common sense.
False. It this were true, why has not every company achieved dramatic productivity improvements in the last 40 years.

8. Lean replaces the need for engineers.
False. Kaizen operates within the boundaries of production standards and established work methods.

Would you like to add to these myths.  If so, please email us at info@gembutsu.com.  We'll be sure to post them.

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