Test your score on these ten points by answering True or False to each.

The Visual Environment

  • Clear visual controls for process flow, issues identification, and process activity are in use and are facilitating improvements in 5s and inventory.
  • Process flow is increasingly visual as workflow’s become more connected and information is conveyed on boards, lights, or with audible signals. Management of status changes is assisted by the environment and rarely becomes disconnected.
  • Nearly all in-process work is controlled through Kanban, queues, or some type of visual authorization. Many process flow decisions are visually guided and made by associates.
  • 5s – Sort Straighten and Shine are completed throughout the facility and are a component of the standard work for both associates and management.

Cultural Behaviors

  • “Takt” is universally used as a basis for resource allocation and process activity, with most scheduling decisions occurring visually and guided by a finished goods policy.
  • Problems are identified and addressed by group leaders with long term solutions mentored by management. Problem resolution does not disrupt flow as the increasingly connected processes allow them to be minimized and contained on-line/real time.
  • Key performance metrics now drive associate behaviors because of their linkage to the overall strategy, and thorough deployment.
  • Skills deployment has evolved into associate ownership of the lean tools, allowing management to increasingly function as facilitators, mentors and teachers.

Lean Tools Usage

  • Primary Lean tools (pull/kanban, 5s, andon visuals, error proofing, standard work, as well as basic error proofing and setup reduction) are now fully deployed, with varied levels of implementation.
  • Advanced Lean tools (Total Productive Maintenance, Autonomation, advanced Error Proofing and Setup Reduction), as well as advanced visuals; are in early stages of deployment..

In a level 3 environment, basic Lean tools are driving great improvement. Sustainability is stabilizing as the associates use of Standard Work, Error Proofing and Visuals elevate quality and output. Skills deployment is migrating to the associates as management develops into teachers and mentors. Performance to objectives is beginning to show big improvements and customer feedback is beginning to fuel engagement.

If you answered “True” to more than half of these questions, you’ve correctly assessed your organization at the “3” level. To learn how to prioritize your lean efforts and turn it into results – watch our LEAP Video on our home page.