Kaizen, six sigma, lean etc all have their place but they're done to death and the marginal gain, except in very high volume manufacturing, is small and not worth as much as an engaged workforce.
The overhead burden of having people dedicated to minute marginal gains is also probably smaller than being innovative and nimble, and having competent marketing people.
Our problem is in large part that we had a GM who worked for the one company for his entire 50 year career, the last 10-20 years of which were spent doing very little in terms of process innovation, or much else really. Being asked to actually get up from his desk and do some work seems to have triggered his retirement which might be good.
Most of the rest of the problem was that his, overpromoted, wife was the production coordinator and she didn't really have a clue. Anything mildly complex had to be dealt with by one of the engineers. Great anecdote "We need to make X units which take Y man-hours and we have one week to do it. How many operators do you need?" "How should I know? Thats an engineer question!".
The occasional panic reorganisation usually resulted in no improvement and a lot of lost equipment. "we've had a tidy up, what do you think?" "Oh fuck..."
Getting a marketing bimbo to put slogans and coloured charts onto posters is not going to turn around 30 years of inertia. Its going to take time and effort and I'm glad its not my problem.
I'm sure most of it is so they can tell prospective buyers "we're a kaizen kanban 5s organisation" so some other mug will buy the place.
Last edited by Dilbert_X (2020-10-16 23:30:07)