A stalled Lean programme, stuck inside manufacturing.
Lean that never left the shop floor.
A family-owned American heavy-equipment manufacturer, founded in the 1940s and employing around 1,300 people, had run a Lean implementation that stalled. The work stayed inside manufacturing and never reached the rest of the company.
The cost showed up everywhere else: late deliveries, too much inventory, and product and production strategies that had fallen out of date, together putting the company's competitive position at risk.
We started with culture, from the top down.
Change begins and ends at the top of an organisation, so that is where we began. With the leadership we reflected on the company's culture, history and heritage, and named the mindset that had made it successful in the first place.
From that we developed a set of company principles connecting past success to a future vision. Managers and leaders went through training built on reflection and discussion, and cross-functional groups tied the principles to real operations. Throughout, we were embedded in daily work, coaching individuals at every level.
One team, not a stack of departments.
The organisation moved from departmental silos to a unified team, with the administrative barriers between departments removed and an improvement culture taking hold at every level. Leadership and employee behaviour changed, communication improved across the company, and Lean, efficient flow reached beyond manufacturing into sales, product development and support functions.
“[client quote - to be supplied]”
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Margins eroding as product and order complexity grew.
A slow, unpredictable path from idea to product.
