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Lean Self Assessment
Lean Self Assessment
Lean Self Assessment
This lean self-assessment will assist you in determining how far along your company is on your lean journey. Read each statement carefully and select the choice that most closely matches how your company currently manages that category. When complete this assessment, your organization will receive a rating and recommendation.
Step 1 of 3
Select the closest match in each category
Workplace Organization (6S) & Visual Management
Wide range of visual management tools used, discipline is high and 6S methods applied throughout
Clean and organized work areas with locations for tools/materials clearly marked and in their place
No workplace organization and all areas generally disorganized and dirty
All production is "make to customer order" with virtually no WIP (work in-process inventory) between processes
Majority of production is "make to customer order" with only standard WIP (work in-process inventory) between processes
Production is "make to stock" and moves through production line in batches with large amounts of WIP (work in-process inventory) between processes
Production is driven completely by "Pull" signal from downstream processes
WIP (work in-process inventory) levels are not always controlled and the "Pull" discipline is occassionally broken
Production flow is completely MRP (Material Requirements Planning) based and is pushed downstream on forecast only
Defect Detection and Countermeasure
There are clear stop procedures in place and team members are empowered to stop the process immediately without approval
Team members can stop the line for quality or safety problems and wait for management to respond
Team members are not empowered to stop the process and are discouraged from disrupting flow
Layout and Design
All processes are linked providing maximum flexibility and communication
Some processes are linked resulting in increased flexibility and communication
Every process is isolated making it impossible to move from one station to the next or communicate
Up-to-date SOP's (Standard Operating Procedures) exist and are clearly posted and followed
SOP's (Standard Operating Procedures) have been developed and some are posted at stations
There are no SOP's (Standard Operating Procedures) and team members work by instinct and tribal knowledge
"Preventative Maintenance" plans exist for all equipment and continually improved
"Preventative Maintenance" plans in oplace for some select pieces of equipment and are followed
Frequent machine breakdowns occur, machines are dirty and there is no "Preventative Maintenance"
Teams are forced to identify root-cause and countermeasures for problems and virtually no problems reoccur
Limited use of problem solving tools but majority of solutions are still "quick fixes"
No use of problem solving tools resulting in "quick" fixes so problems constantly reoccur
FIFO (First In, First Out) consistently utilized and no material is found outside designated areas
Formal system to support FIFO (First In, First Out) is in place, but lapses occur due to lack of discipline and/or weak design
FIFO (First In, First Out) is not practiced and it is difficult to identify locations and levels of inventory
Total Assessment Score
Congratulations! You are well on your way to building a "world class" lean organization but the journey never ends. Continue to drive continuous improvement activities to maintain and improve your competitive edge. Call today to explore Exceeda's offerings of advanced lean tools and techniques to take your skills and proficiency to the next level.
You have begun your lean journey, you are on the right track and change is becoming visible. Exceeda can accelerate your lean journey by teaching and applying the technical tools and methods required to streamline operations, eliminate waste and deliver exceptional customer value.
Taking this self assessment is the first step in beginning your lean journey. By taking the time to complete this self-assessment, you recognize that the adoption of lean tools and techniques are required to remain competitive. You should have Exceeda perform our 15 point on-site lean operational assessment to evaluate your organization. We will identify activities and develop the roadmap to address areas for improvement.