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

The Visual Environment

  • Clear visual controls for process flow, order and issues response are in limited use, but response primarily comes from management personnel.
  • The flow of information, products, materials, and management of status change is supported by progress boards and some visuals but is sometimes disconnected.
  • Some Kanbans control production and allocate resources, but they aren’t used facility wide and don’t enable associate-level decision making.
  • More than half of the facility has completed Sort Straighten and Shine from 5s, with public areas such as break and lunch rooms receiving consistent attention.

Cultural Behaviors

  • “Takt” is posted and used in some areas for resource allocation, but not facility wide. Changeover and scheduling decisions are typically initiated by group leaders, however most scheduling remains primarily manual.
  • While most problems are identified by group leaders, improvement efforts and Issue response are led by management with associate participation. Problem occurrence impairs flow as the disconnected processes push resolution off line – delaying results.
  • Key performance metrics are posted, updated, and understood organization wide
  • Lean skills deployment has begun at the management level, with facilitation’s and tools expertise now residing at the supervision and manager levels.

Lean Tools Usage

  • Value Stream Mapping has been used to document the various value streams. The use of primary Lean tools (kanban, 5s, andon visuals, Error Proofing, Standard Work and setup reduction) is progressing and is in the midway through site-wide deployment.
  • Advanced tool use (Total Productive Maintenance – TPM, Autonomation, preventive Error Proofing, and other advanced visuals) is pocketed or in early stages of deployment.

In a level 2 environment, improvements based on tools usage are beginning to appear. Associates exposure to Standard Work, Setup Reduction, and other enabling tools is elevating quality and output. Skills deployment is primarily at the management levels as they develop into teachers and mentors. Performance to objectives shows improvement, but sustainability remains fragile.

If you answered “True” to more than half of these questions, you’ve correctly assessed your organization at the “2” level. To learn how to improve your lean program and begin generating results – watch our LEAP Video at www.youtube.com/chautauqua011 contact sales@chautauqua-llc or call 260.927.4112