One Man’s Lean Journey: If You Follow the Process, The Results Will Come
One of the most valuable lesson I learned while working in the automotive industry wasn’t about the industry or people or even myself. The most valuable lesson I learned was having a great process will yield predictable results. I didn’t learn this from a manufacturing process. Instead I learned this from a problem solving process.
The automotive supplier I worked for was part of the Chrysler Supplier Quality Program. As part of that program, I got to learn different methodologies for problem solving. One was Shainin’s Red X methodology. I followed the methodology stringently. The benefit was repeatedly achieving great results.
One example was the with the electro-plating line. This is a large vats of chemical baths that produced a chrome finish on plastic parts. The line was operating at a 84% yield. Any defects that came out of the line had to be trashed. The parts could not be salvaged. We were throwing away approximately $40,000/week in scrap. I was asked to problem solve the scrap and get the yield up.
I knew squat about chemistry then and I still don’t know squat. In fact, I needed a tutor in college to get me through freshman chemistry. But that was my task.
Following Shainin’s Red X methodology and never wavering from the process, within in two years the plating line was running at a 96% yield. The line had never ran above 91%. Scrap dollars were down to $10,000/week.
I learned that I didn’t have to know anything about an area to achieve significant results if I followed a good process. It is something that is stated repeatedly in the lean world, but until you have the experience it is hard to truly understand the power of this.
I was accused of “always being right”. I never said anything of the sort but when I was accused of that I would say, “Yes, because I follow the process not because I know anything.”
Have you experienced a good process that is predictable and repeatable?
- A good process is more powerful than hero employees
- You don’t have to be an expert in an area in order to produce significant results
- It is easier to stick to a process when you are unfamiliar with the area, because you can’t rely on your “expertise”