Why lean manufacturing can fail

The reasons that are most common for lean manufacturing efforts to fail are:

The failure of managers and especially senior level managers to fully understand the lean manufacturing system that is being implemented. If the leaders do not completely understand and are not fully committed to the process, it will not work.
Managers try to implement only specific components instead of the entire approach. For instance, may they would just try to use the 5 S system but this is only one tool to help the process be more successful. The elements of the TPS approach are integrated as well as interdependent. They must all be implemented for success, not just one of two of the components (Convis, 2001, p. 64).

Industries that could use lean manufacturing

Northrup Grumman provides a good example of how well the 5 S system can work. The company first implemented the 5 S system on a part of their delivery process. The work area was changed from different components into a single product. Prior to using this system, the area was disorganized and inefficient. Using this system, however, reduced the space employees needed to travel to complete their tasks by 93 percent. They also realized a 42 percent reduction in the total floor space used (Skinner, 2001).

Why lean manufacturing can fail

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