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  • 1.  Who's Had Exposure to Lean and what is your experience?

    Posted 21 days ago

    Somewhere in the early 2010s, when I was working in R&D, I was told we needed to start applying Lean. It was a short-lived exercise in futility. There was no organizational or leadership will, and the name was a turn-off. I've come to better understand Lean from reading about the auto industry

    I view the purpose of many processes to overcoming a natural tendency toward bad behavior, knowingly or unknowingly. People like to work on what they're good at or find fun, not necessarily on what's needed. There is a natural tendency to control information to gain power. Collaboration requires sharing recognition, assuming a job well done. Decision-making is hard. Lean is a catchall for doing these things and more well.  Not a bad concept.



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    Mitch Winkler P.E.(inactive), M.ASCE
    Houston, TX
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  • 2.  RE: Who's Had Exposure to Lean and what is your experience?

    Posted 17 days ago

    I worked for automotive related businesses from 1985-2016 and witnessed (participated) in most of the quality systems developed and modified primarily by Toyota and GE Aerospace. They all had the original concepts of TQM embedded in them which was valuable because once you understand how to establish and mature teams, managers can use the concepts to create teams "on the fly" to deal with most issues that arise in manufacturing. The problem comes when users force conformance to a structured system like Six-Sigma or Lean that were never designed for. For example, Six-Sigma was designed around statistical analysis but most companies I worked for tried to force-fit services into the model. That never worked and only served to give purchasing agents one more tool to squeeze price concessions from suppliers.



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    Henry Phillips P.E., M.ASCE
    Environmental Engineer
    Brush Creek Environmental Services, LLC
    Freeport FL
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  • 3.  RE: Who's Had Exposure to Lean and what is your experience?

    Posted 14 days ago

    Mitch – I would say we all had exposure to some degrees of Lean way of doing things since childhood. Perhaps not being aware of the term itself – but elements of it have been there. The likeness of: don't keep water running in the faucet while doing something else, only take in the plate what you can eat and finish . . . these sorts of things.

    Apart from what we are accustomed to hearing about lean and thin fashion models – the term is often confused and is used in parallel with being minimalist. The underlying idea is that resources (traditional and Natural, to be exact) are finite – and one needs to be diligent what one does with those limited resources, keeping in mind the long-term view of things. Thus being sustainable is another appropriate world for being lean (we have discussed it in other threads).

    Since the dawn of Industrialization – social slogan switched to consumerism. The mantra is like this: consume and keep consuming – industries continue producing all sorts of manufactured resources – so there is nothing to worry about the depletion of resources.

    And, yielding to the pervasive pressure of advertisements, we tend to accumulate things that are – well, something we can live without. It's the backbone of an economy!

    What do being Lean and Sustainable mean then? We often forget that there is another word for these terms – it is called Simplicity. I have tried to emphasize about it in the Artificial Intelligence essay and others. In Leonardo da Vinci (1452 – 1519) words: simplicity is the ultimate sophistication.

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    Dr. Dilip K Barua, PhD

    Website Links and Profile



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  • 4.  RE: Who's Had Exposure to Lean and what is your experience?

    Posted 10 days ago

    When I was serving on the Air Force Secretariat Staff in the Pentagon a while back, the senior leaders embraced Lean and Six Sigma principles with some "downward" direction to incorporate its principles.  We all ran out and bought the books and "got smart".  What I saw essentially was another effort to "recolor and rebrand" many common sense techniques and principles already in place.  However, it did require us to relook what we were doing and confirm we were already on the right track in many instances.  My prime take-away benefit was it made you look in the mirror and confirm we are operating effectively and efficiently and not in the "this is the way we have always done it" mode.

    When I was on active duty in the late 80s and early 90s, we were introduced to TQM.  Same as Lean, it was just a relook at efforts to operate more effectively and efficiently.

    To me, both efforts strive for you to work smarter, not harder which I think we all embrace.  But don't let this interfere with prior proper planning for the sake of a new tool in the toolbox.

    Two sayings come to mind:

    (1) don't let this become a solution in search of a problem

    (2) Problem solving is about 95% of the time defining the problem and 5% of the time implementation of the solution.



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    James Holland EIT, M.ASCE
    Alexandria VA
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  • 5.  RE: Who's Had Exposure to Lean and what is your experience?

    Posted 8 days ago

    Hi,

    My organization offers the Six Sigma courses and I took the first level.

    They are trying to change the culture of the organization.  

    My observation is that if the people making decisions are not incorporating it into their way of doing business it will not change much.  It does provide hope, however.

    We also had to take the FEMA emergency management courses.  The ones where it explains that you should control who responds, have a single manager, span of command, etc. EVERYONE had to take it.  From upper management down to the first level of supervision.  

    Everyone still shows up at an emergency, the people managing the emergency took the course but never incorporated it into their mangement.

    In a large organization it is hard to change the culture, hard to make sure that management is competent at all levels.  People are complex but we are much better in small groups than in large.  At least that has been my observation.

    Echoing the points made by Henry Phillips and James Holland, systems that work for one environment, may not be applicable.  It goes back to the adage, "to someone with a hammer, everything looks like a nail."

    If Six Sigma and lean processes change things here I will be very happy, I welcome each and every improvement that we incorporate into our company.



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    Sarah Halsey P.E., M.ASCE
    New York NY
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  • 6.  RE: Who's Had Exposure to Lean and what is your experience?

    Posted 7 days ago

    Your connection between 'Lean' and the Incident Command Structure (ICS) is not something I had thought of, and it makes perfect sense. 

    You comments and those of others support my experience that processes like 'Lean' fail to deliver the intended value when applied to routine work. 

    The comparison with ICS shows what's possible. Sadly, it takes an emergency situation to get this value. This has also been my experience. 



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    Mitch Winkler P.E.(inactive), M.ASCE
    Houston, TX
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  • 7.  RE: Who's Had Exposure to Lean and what is your experience?

    Posted yesterday

    Dear all

    As you may now, LEAN is about reducing waste by delivering a product or service when needed and in the quality needed. The problem in design is often that additional background studies are needed which the Client may not understand, considers an unnecessary detour and is not willing to pay for. It is quite a communication task to explain how the project would benefit from exploring the 'solution space' and reducing contingencies otherwise needed to cover uncertainties.

    Rather more in favour is "Lean Construction" meant to provide the Contractor on the construrction site with exactly the right information at the right time (JIT). This is mostly associated with the Last Planner System (the pull principle applied to construction processes). When suggesting further reading in our new FIDIC quality guide, I chose the following reference from UC Berkeley:

    But also literature on the application of Goldratt's Theory of Constraints (TOC) to 'critical chain' project management (CCPM) is worth reading, e.g.



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    J.-Martin Hohberg
    Dr.sc.techn, M.ASCE FED
    Sr. Consultant, IABSE e-Learning Board
    Bremgarten / Berne, Switzerland
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  • 8.  RE: Who's Had Exposure to Lean and what is your experience?

    Posted 2 hours ago

    I don't have direct hands-on experience implementing Lean, but I find your perspective very relatable.
    In construction and infrastructure projects I often see similar challenges - fragmented processes, information silos, and the gap between planning and budgeting.
    From my perspective, many of the ideas behind Lean align strongly with improving coordination and transparency across project teams.
    It's interesting how much the success of these approaches depends on organizational culture and leadership support.



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    Darya Stanskova M.ASCE
    Cost Estimator, Construction Engineer, Power Engineer, Project Manager
    Fort Myers FL
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