![]() Use Process Mapping to Identify Bottlenecks It only takes one person to continually make mistakes or poor decisions that increase costs. When company leaders announce a lean transition, they must draw attention to how every person plays a vital role in helping it happen. Additionally, the study’s authors emphasized that success happened due to executive buy-in coupled with active involvement from all team members. One of the conclusions was that the processes used at the plant contributed to the failure rates. The company moved ahead with a five-stage roadmap that included measures to identify the root cause of rejection rates, fix those issues, and develop a plan to minimize future problems. However, when company leaders emphasize that everyone plays a vital role in improving the organization, the team effort should become apparent in the results.Ĭonsider the case of a Portuguese aluminum gravity die-casting plant that used the Lean Six Sigma method to reduce defects. Making the transition to lean processes often doesn’t come naturally to employees. Encourage All Employees to Take Ownership Here are some proactive ways to use lean manufacturing to keep expenses down in a foundry. Not surprisingly, companies that successfully implement that approach often find their costs dropping over time. The lean manufacturing process focuses on ways to improve quality while reducing waste.
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