As a part of the Weekly Lean blog series we have learned about History of Lean manufacturing? in last weeks blog, this week we will learn the Most common challenges faced in implementing Lean in your factory. 

Implementing Lean Manufacturing is not a cakewalk journey for any industry. Every industry has its own challenges, Based on our past 10 years of experience in Lean implementation we have consolidated 5 most common challenges that we face during our Lean implementation in this blog.

What are the 5 Common Challenges in Implementing Lean? 

1. Lack of Senior Management Commitment
2. Unorganised way of working / too much fire-fighting / lack of planning
3. Internal Ego / Office Politics / Unwilling to learn
4. Change in Priorities
5. Resistance to Change  / Job Fear / Insecurity 

Most of the challenges are based on attitude, behaviour and lack of participation. 

1. Senior management commitment in Lean implementation

Number One reason why many lean initiatives fail…

• In many companies, the senior management thinks that their team should change and continuously upgrade. What they do not understand is that the change should happen from them. 
• Lean Initiatives have to be owned by the senior management. Consultant is not the owner of the lean initiatives
• Sometimes, the senior team participates inconsistently, which sends a mixed signal to the champions and other employees. Senior team should give a very clear signal that they are actively participating in the lean program.

How to Overcome this challenge? 

1. Show your commitment
2. Participate in lean programs
3. Talk to people regularly on lean activities
4. Motivate them. Do not yell/shout at them
5. Take pledge with the employees
6. Participate in Rewards and recognitions

2. Unorganised way of working

Lack of Focus, Fire-Fighting and lack of planning

• Too many changes in the production plan, materials non-availability, employee absenteeism, poor quality, Customer complaints, etc are the results of lack of focus / planning by the Middle management
• This creates frustration and stress for all the employees
• In this state, people would not welcome any new initiative from the management. 

How to Overcome this challenge? 

1. Middle management to plan and execute the production properly
2. Do not give false promises to customers and employees
3. Planning solves 80% of the issues 
4. Take Charge of the situation

Here we are at the end of the third blog of the Lean Series. Now we have learned about the two common challenges faced in implementing Lean in your industry, Next week we will see about the remaining three challenges in detail.

It is so important to introduce Lean Manufacturing in your company and where can we use the Lean Philosophy to reduce the wastes and improve productivity, If you want to implement Lean in your company contact us.

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