A new path: How I first became a believer and then a prophet of Lean

“Lean is a way of thinking – not a list of things to do” (Shigeo Shingo)

I started working in the automotive industry in 1999. However, I didn´t heard about Lean until several years later. Why?

First of all, because Lean itself leads to a cultural change and undoubtedly, cultural changes are often the most difficult to achieve and the most “expensive” in terms of time.

Secondly, even though Lean was born more than 70 years ago, it´s just since a couple of decades that we began in Europe to take it seriously. To make matters worse, the Lean transmission machinery and Lean tools implantations unfortunately does not run as fast a F1 racing car, but easily as a windmill (those who Cervantes' Don Quixote tilted at, mixing up with giants). Slowly but surely.

These two factors (being a "youth philosophy” and with a “slow speed” in knowledge sharing) haven´t led Lean to be recognized as the powerful way of thinking that it represents, only since a few years ago.

The automotive industry has been the field in which Lean (often called Lean Manufacturing) was born. And it has been there where it has achieved its main implementation, as Lean tools have currently a widespread use. But fortunately for all of us, Lean spreads itself more and more through different fields and this is occurring ever faster. Its progression is becoming geometric (instead of arithmetic) . That’s not just important – It´s terrific.

Finally, about 10 years ago, I got in touch with Lean for the very first time. In my company, as in many others, the Lean methodology was applied but, of course, by changing the name “Lean” to something more corporate (which on the other hand is certainly understandable, due to the image and adhesion that this change can bring to the company) and started using and taking advantage of their tools. I was at that time team leader on one of the BIW (Body In White) areas and the legacy I had received from my ancestors made me initially susceptible to be resistant to change. I´m sure that you´ve heard before this “know how” rules from these kind of people, like "it has always been done that way “ or "why should we change our way of doing things?”.

However (and luckily), there were no resistance at all. As it occurs sometimes in life, when you fell in love at first sight with someone or something, that´s right what it happens between me and Lean. From the very beginning, by starting to know tools like TPM or 5S, I realized the simplicity of the method and the benefits that could be achieved. Soon I was a fervent believer in Lean and its tools.

A little bit later I was again lucky to be chosen as the Lean Manager for the BIW area. Even though I must admit that I had (and have) a lot to learn, I became soon a Lean prophet. But not because of what my function could demand, but because my absolute assimilation of Lean as a way of thinking.

Since then and as Lean is “alive”, I keep on learning about it and trying to improve permanently. Continuous improvement knows no bounds, you know.

In this blog I will share my point of view on Lean and I´ll try to answer what makes Lean a “Must” in any industry and even in any aspect of life.

I´d like to take the opportunity also to thank all these people who have shared their knowledge –of which I've been a customer for a long time. And after that, I´d love to contribute to the Lean dissemination. Why not taking part in this sharing process and Lean value stream also as a supplier?

PS.: Considering this issue from my point of view.

See you LEAN.