This blog is a continuation of the Previous blog 5 common challenges in Implementing Lean Manufacturing in your company, this week we will learn the remaining three common challenges faced in implementing Lean Manufacturing in your factory.

3. Internal Ego / Office Politics / Unwilling to learn

People come with their ego’s and mindsets. How to change this?

• Everyone looks at the world through their eyes and their experience
• With experience comes the mindset, ego and behaviour
• In many companies we have seen managers from same functions, who cannot agree on anything. How do we bring performance in this case?

How to Overcome this challenge? 

1. Training can be provided on Emotional Intelligence, understanding oneself
2. Soft skills program combined with games / activities which improves TeamWork, positive attitude etc.
3. Create common projects for people who cannot work together

4. Change in Priorities

Sometimes, focus may change to a critical business activity (resulting in lack of focus on lean)

• In this every changing world, there are challenges which may arise suddenly resulting in a complete change of focus. E.g. the Corona Virus and the impact in the year 2020. China, the world’s manufacturing powerhouse, literally came to a halt and resulted in a global meltdown
• Sometimes the focus shifts on other routine but important activities like External Audits on ISO, OHSAS, Buyer Requirements, New Projects, Government related regulations, etc.

How to Overcome this challenge? 

1. Senior Management to be committed for the Lean transformation
2. Time management Tips for senior management to focus on all the important initiatives
3. Remember, Lean is a Long Term Initiative. It is not urgent, but very important.

5. Resistance to Change

People may perceive Lean as a tool to reduce manpower / create fear

• In general, people are cynical / not willing to change / accept anything new, especially in their workplace
• Company would have taken many initiatives in the past, to reduce manpower. So this comes to their mind when they se lean initiatives also. 
• Employees generally approach any new initiatives with a fear, indifference or with a negative approach (all of these were based on the past behaviour of the senior management)

How to Overcome this challenge? 

1. Assure the employees that this program is for the benefit of the people
2. Do not use negative reinforcement (punishment/fines/penalty) for lean activities
3. Senior management to consistently motivate the employees

Here we are at the end of the Fourth blog of the Lean Series. Now we have learnt about the three common challenges faced in implementing Lean Manufacturing  in your industry, Next week we will learn about What is Work & What is Waste interns of Lean Manufacturing. 

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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