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The Lean Benchmark Report

Table of Contents

Executive Summary .............................................................................................. i Key Business Value Findings.......................................................................... i Implications & Analysis ................................................................................... i Recommendations for Action..........................................................................ii

Chapter One: Issue at Hand.................................................................................1 Lean Maturity: Operational Factors................................................................ 2 Lean Maturity: The Culture Factor ................................................................. 4

Chapter Two: Key Business Value Finding...........................................................7 The Best-in-Class Tackle Lean: Strategic Actions.......................................... 8 The Best-in-Class Tackle Lean: Mastering the Basics ................................. 10 5S (Sort, Set in Order, Shine, Standardize, Sustain)............................. 10

Value Stream Mapping (VSM)............................................................... 10 Line/Workcell Manufacturing................................................................. 11 Kanban.................................................................................................. 11 Identification of Improvement Opportunities.......................................... 11 Education Lean Methodology................................................................ 11 Technology-Enabling Lean Processes......................................................... 12 Pressures, Actions, Capabilities, Enablers (PACE)...................................... 14

Chapter Three: Implications & Analysis.............................................................15 Exceeding Expectations: Behind the Numbers............................................ 16 Driving Operational Performance with Metrics............................................. 17 The Role of Technology ............................................................................... 19 Stacking Up Against the Competition........................................................... 22

Chapter Four: Recommendations for Action ......................................................23 Laggard Steps to Success........................................................................... 24 Industry Norm Steps to Success ................................................................. 25 Best-in-Class Next Steps............................................................................. 25

Featured Sponsors............................................................................................. 27

Sponsor Directory ..............................................................................................31

Author Profile .....................................................................................................32

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