Blackbootz : you are correct in your initial assessment of Lean. In theory it's exactly like ButterflyEffect describes it. In practice it works nothing like the theory. Lean suffers badly from bad data and bad incentives. It fails to account for people naturally wanting to cheat and cut corners thereby requiring the non value added steps it so boldly try's to eliminate. I liken lean and six sigma to being a corporate version of communism. It sounds great in theory but in practice it's poorly implemented and does not work well. Dispite that its proponents keep championing it as a magic bullet saying that all failures are a result of improper understanding of lean and all successes being a direct result. As a concequnce lean and six sigma are much like corporate versions of religion where the successful are true believers and the failed are heathans. If you want to know what lean truly looks like and not the theory that you read in text books and promo videos, stop by the cactus moon bar on a Friday after 3pm and ask some Boeing mechanics. You will get some awesome stories of spectacularly expensive failures.
I'd agree with both of these things but faulty data...that's prevalent everywhere. Research, government studies, manufacturing, that's not necessarily a shortcoming of Lean so much as a shortcoming of a person's ability to ensure data quality, which is arguably the harder part of the equation. As for human behavior, that's a tricky one. Plus, it's near-impossible to ensure consistency across people doing the same exact thing. Which is frustrating, however, I do think it can be successfully implemented if data quality and the inclusion of operators and such into it's implementation are accounted for. It shouldn't just be a tool of the engineer or equivalent.Lean suffers badly from bad data and bad incentives. It fails to account for people naturally wanting to cheat and cut corners thereby requiring the non value added steps it so boldly try's to eliminate.
Haha, is the Cactus Moon a bar by the factory? Where is the main Boeing factory? It sounds like, according to you, that lean Six Sigma and communism make faulty assumptions about human behavior and motivation. Where did you gain such insight/experience of lean Six Sigma?