1) Lean manufacturing requires both industrial engineering and operational discipline to succeed. Industrial engineering focuses on designing efficient manufacturing systems while operational discipline ensures consistent execution of operations. 2) Without operational discipline, lean improvements cannot be sustained and estimated benefits will not be realized due to deviations from standard work. 3) The author offers consulting services to help manufacturers achieve operational excellence through principles of lean, six sigma, and agile manufacturing. This includes reducing costs, increasing throughput, analyzing business cases, and ongoing process improvement support.

1. Why Lean Can’t Succeed Without Operational Discipline
Author:
Calvin Williams
Principal / Continuous Improvement Strategist
Manuficient Consulting
Manufacturing Strategy, Analytics, & Implementation

2. Perfecting the manufacturing system is an art; however,
executing the One Right Way is an exact science
Manufacturing Art vs. Science
Art Science
Plant and Layout Design
Process design & engineering
Continuous Improvement
Changeover Execution
Performing Quality Checks
Developing Standard Work Procedures
Executing Standard Work
Performance Coaching and Feedback
Talent Development
Performing Root Cause Analysis
Executing Preventative Maintenance
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3. Front-line supervisor / manager effectiveness can be measured
in terms of the number of deviations from the One Right Way
Manufacturing Management Effectiveness
Operator A Operator B Operator C
Operator A Operator B Operator C
Maximize:
• Quality
• Service (reliability)
• Morale
Minimize:
• Cost
• Safety Risk
Results
Disciplined Process Execution
+250%
+140%
+321%
0% +10% +8%
Maximize:
• Cost
• Safety Risk
Minimize:
• Reliability
• Morale
• Quality
Results
Identifying and becoming disciplined to One Right Way
minimizes operating cost while maximizing reliability
Identifying and becoming disciplined to One Right Way
minimizes operating cost while maximizing reliability
The ultimate measure of production management
effectiveness is the disciplined execution of operations
Out of Control Process Execution
Illustrative

4. Lean can be broken down into two base components: Industrial
Engineering and Operational Discipline
Base Components of Lean Manufacturing
Industrial Engineering Operational Discipline
The process of designing and implementing the
perfect manufacturing system
The consistency of actions taken to execute
operations
Lean Manufacturing
The Systematic Elimination of Waste

5. New Plant or Process
Design &
Implementation
Plant or Process
Optimization
Industrial Engineering is the process of designing and
implementing the perfect manufacturing system
Components of Industrial Engineering
New Plant or Process
Design &
Implementation
Plant or Process
Optimization
Optimization consists of continuously improving the performance of
key aspects of performance
Cost Safety Risk Quality Service Morale
Plant / Process Design
consists of creating and
implementing a system of
converting inputs into
desired outputs
Examples of Lean (IE) Tools
Kaizen
Root Cause Analysis
Poke-a-yoke
Hiejunka
Kanban
Hoshin Kanri
…Many Others

6. • Key Points
• Discipline can be driven without the application of
Industrial Engineering
- It is the result of disciplined leadership
• Operational Discipline helps to understand the
relationship between Six Sigma and Lean
Operational discipline is the consistency of actions taken to
execute operations
Operational Discipline
Distribution of Process Completion Times
Out of Control Process Distribution Disciplined Process
Distribution
1σ 2σ 3σ 4σ2σ3σ4σ
6σ
1σ 2σ 3σ 4σ2σ3σ4σ
6σ
Front-line Supervisor /
Management performance can be
measured in operational discipline

7. Without operational discipline, Lean improvements cannot be
sustained nor can estimated benefits be realized
Lean & Operational Discipline
Actual
Average
Target
-60%
-37%-68%-37%
-76% -76%
-62%
Process Execution Times
The gap between actual
and target performance
results in increased
cost and reduced plant
reliability
Actual Cost Target Cost
Missed Opportunity
Process Execution Cost
Maximize:
• Cost
• Safety Risk
Minimize:
• Service (reliability
• Morale
• Quality
Results
Illustrative

8. We offer an array of services to help manufacturers across
industries to realize their business objectives
Manuficient Service Offerings
Operating Cost
Reduction
Optimize process
efficiency to increase
labor and asset utilization
Production
Throughput Increase
Eliminate process
bottlenecks to unlock
untapped capacity
Material Cost
Reduction
Close material loss points
and/or identify favorable
sourcing options
Business Case
Analysis
Evaluate overall business
impact to support
decision-making
Should-Cost Analysis
Determine what a product
should cost to make or
procure
Network Optimization
Assess the optimal
manufacturing footprint
and associated benefit
Efficiency &
Opportunity Analysis
Provide on-going
process improvement
support
All services are
founded in
principles of Lean,
Six Sigma, Agile
Manufacturing and
other leading
disciplines designed
for operational
excellence

9. Contact Details
Calvin L. Williams, MBA, BSIE, LSS
Principal / Continuous Improvement Strategist
(404) 480-2307
calvin.williams@manuficient.com
Manuficient Consulting
Manufacturing Strategy, Analytics, & Implementation
2300 Holcomb Bridge Rd Suite 103-103
Roswell, GA 30076
www.manuficient.com
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