I recently had a conversation with John W. Davis, author of Progressive Kaizen:: The Key to Gaining a Global Competitive Advantage and president of WFM Associates, and he discussed what he call "misguided pragmatism" in regard to Lean initiatives in US companies. I asked him to elaborate and here was his response:
It has been well over a decade since US industry was introduced to the Toyota Production System (TPS). During the same period, US manufacturing has gone through the greatest surge of plant closings and layoffs since the Great Depression - and the trend seems far from over. At first glance, this would serve to leave the impression that Lean Production has not been the panacea it was touted to be. But is the culprit Lean itself or how US industry typically aligns itself to the task?
That is a question that has and will continue to be explored in corporate offices and boardrooms across America. But to do the matter justice, the issue of conventional mindset and its impact simply cannot be ignored. Misguided pragmatism comes to bear when management accepts the need for change, but holds strong proclivities related to the way business has always been conducted. Coupling this with pragmatism surrounding the value of the change itself and the result will always be a restriction in the depth of Lean implementation pursued.
If the ultimate mission, assumed or otherwise, is to implement some of the tools of TPS, efforts will be applied at inserting various levels of Kanban, SMED, Poka-Yoke, etc. On the other hand, if the mission is aimed at fully and irreversibly changing the system of production (and is clearly understood as such by all concerned), strong efforts in achieving that goal can occur. The driving objective has to be more than making incremental improvement to an old and cumbersome system of production. It has to be aimed at establishing a mindset that a full and complete change to the system of production is absolutely crucial. If that one point is effectively understood, everything else will tend to fall in place.
What do you think of John's opinion? Do you feel that Lean initiatives have the tendency to merely "shine and polish" an outdated system instead of creating a transformation?
