Hasten Issue resolution
A new process requires
significant amount of support to resolve abnormalities. All functions must
provide priority attention to ensure that the benefits associated with the
change are achieved, maintained, and subsequently improved upon.
The river and rocks is an
analogy that is often used to demonstrate the need for rapid Issue resolution.
See figure 15. The water level on a river is quite high, concealing all the
rocks on the river floor. The water level is a reflection of the fat or waste
in the process; the rocks relate to the problems or abnormalities in the
system. As the fat or waste in a system is eliminated, the water level
drops. This exposes more rocks. A company must tackle and eliminate each
abnormality as it is exposed in order to strengthen its manufacturing
operations. Management must avoid the temptation of reintroducing
inefficiencies (the fat) in an attempt to conceal these abnormalities once
15 The river and rocks analogy
Develop subconscious competence
Key to maintaining the model
value stream is for people to develop a state of subconscious competence.
This means that people habitually conduct their activity in a way that supports
the lean manufacturing methodology. This is not easy to achieve, and normally
companies evolve several times before attaining this ideal state:
1 Subconscious Incompetence - They dont know what
2 Conscious Incompetence - They do know what
3 Conscious Competence - They know what they
do and try hard to achieve it.
4 Subconscious Competence - They habitually
An example of the evolution states is learning to ride a bicycle. Most
people can probably now ride a bicycle without even thinking about it they are
subconsciously competent. But to get to this stage one progressed from having
tried to cycle and not being able to conscious incompetence to being able to
ride only by fully focusing on task conscious competence.