Lean Manufacturing Principles- Can LEAN be used to reduce workforce errors? - Dudley Child Executive Recruitment

Lean Manufacturing principles have been implemented throughout the manufacturing and engineering industries for over 2 decades and continue to be rolled out in other sectors more recently. Derived from the Toyota Production System (TPS) Lean essentially is a process by which an organisation strives to improve efficiency and in doing so reduces waste.  Lean manufacturing principles utilises tools which allows a company to start and continue on its path to creating a Lean culture and this typically include 5’s, Kanban systems, Kaizen, JIT, Poka Yoke, Value Stream Mapping, JIT, as well as others.  However the question is whether these Lean principles are able to reduce errors by the workforce?

The key areas involved are – SOP- Standard Operating Procedures.  It is vital that these SOP’s for all job functions are not only clear and robust but that training is provided to all so as to reduce misunderstanding. 

Another area to be looked at is an organisational’s Poka Yoke system i.e. error proof/ fail safe.  Machinery usually has in-built poka yoke systems already in place but employees need the same treatment as well.  These can be visual, such as clear bold signs or physical, which could be one way locks on a door.

One of the most important ways in which Lean can reduce human error is inspection.  “Inspect what you expect” is a common phrase used amongst managers nowadays and inspection and checking is a far better way of motivating staff rather than “don’ts” of prevention.  In a way it is positive confirmation rather than negative avoidance.

The final process is to utilise the LEAN tool of a FISHBONE diagram (ISHIKAWA OR CAUSE AND EFFECT).  By examining areas where failure/ errors may occur, you add preventions/ measures.  It is similar to PPM scheduling for a maintenance department in a manufacturing environment, in that you are being pro-active rather than reactive.  This way you have clearly identified from the beginning where the problems/ errors may occur and what needs to be done to countermeasure it.

For more information on LEAN manufacturing principles including TQM, TPM, Kanban systems, JIT please visit www.dudleychild.co.uk

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