Lean: Finding the Human Element
Lean and Green
By Fernie Grace Tiflis   
Tuesday, 01 May 2007
smc While lean manufacturing is geared toward reducing waste, the human side of it is about respecting people, according to Strategos Inc.
While lean manufacturing is geared toward reducing waste, the human side of it is about respecting people, according to Strategos Inc.
People are great when given the freedom to think, but most companies find the technical side of lean manufacturing easier and more straightforward than having to change the human side of it. Most of the goals of lean manufacturing predate even the 20th century, but as Kansas City, Mo.-based Strategos Inc. reports, it has only been about 25 years since lean made a considerable impact in the United States.

Still, the organization argues that “most manufacturers talk big but implement poorly, [and] more than anything else, problems on the human side are responsible for this tardiness.” While lean manufacturing is geared toward reducing waste, the human side of it is about respecting people, Strategos says. It’s about promoting free thinking and looking at things to improve within the company using the core disciplines of lean as a guide, according to the organization. Unfortunately, almost every company ,at some point, falls short in recognizing the human element while embarking on the lean journey.

Champion Laboratories Inc., a filter manufacturer for the automotive and heavy-duty industries based in Albion, Ill., practices lean by making things visual for its employees.

It is not just about reducing waste. “It’s about making people understand – helping employees know what their targets are and providing the support to reach them. That is an important side of lean that is looked over a lot,” Vice President of Operations Warren Morrow explains.

For example, Strategos videotaped a group of workers that showed how they designed, built and operated their own workcells. It showed how the social and technical interaction changed how employees viewed and responded to their daily work. Strategos says employees noted how working on their own workcells has changed their attitudes, relationships and quality of work-life.

Probably the easiest approach – but equally important to the human side of lean – is teamwork. Some companies, such as Champion Laboratories, already emphasize teamwork. Its president, Camilla Denison, notes that her company offers constant training to help employees understand lean. “We teach them on why [lean] is important and why we’re doing it,” she says. “The more they know, the better they understand and [they give us] better suggestions [on how to improve].”

Although having people work together is no easy task, Strategos says, teamwork enhances lean manufacturing significantly. “Teamwork provides superior motivation, enhanced coordination, improved problem-solving and better decision-making,” it explains. “Teams require training, compatible workflow and organizational structures, understanding management and patience.”

Strategos adds that teamwork should involve communication and coaching. Employees can hold meetings to discuss the development of their own skills that will be beneficial to the company. In addition, management should be skilled enough to encourage the advantages of lean, and at the same time, listen to its people and consider their suggestions to move toward a lean-focused environment. For more information on Strategos, visit www.strategosinc.com .
 
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