Get Your Manufacturing Business into a Lean Rhythm

When it comes to the methodology you use to run your business, you do not have to choose A or B—you can embrace the power of the A-N-D. I was reminded of this recently when I visited a manufacturing Rhythm client.

They have been using Rhythm as the Operating System to run their company for years, consistently deploying Think, Plan, Do. To gain efficiency and reduce waste, they have also begun integrating Lean Manufacturing.

In the manufacturing industry, where it is critical to regularly refine and streamline processes, the combination of Rhythm and Lean is a secret recipe for success.

Rhythm Sets the Foundation

With Rhythm, manufacturing companies develop a foundational framework for their strategy execution activities. These rhythms, in particular, are key:

• Quarterly Planning. During this time, teams discuss and choose their strategic Priorities. This is similar to a Lean Hoshin meeting; Hoshins are the Lean equivalent of Rhythm Priorities. Rhythm provides best practices, thorough agendas, robust software tools, and even facilitator support to ensure these meetings are focused and productive.
• Early Warning System (EWS). Establishing leading indicators to build an EWS is a key element of the Rhythm methodology. This allows teams to quickly catch issues and make crucial adjustments to get back on track.
• Weekly Adjustment Meetings (WAMs). A WAM is not a general status report or read-out of recent work; instead, it is structured around a dashboard of goals that the team reads like a heat map to identify and unpack problem areas. WAMs continually re-orient teams towards success, helping them build positive momentum throughout the quarter. 

Bring in Lean to Maximize Efficiency

Lean easily complements the Rhythm methodology and helps companies reduce waste. Here a few practical ways you can combine the two:

• Uncover your Hoshins—or Priorities—through the strategic discussions you hold in your Quarterly Planning meetings.
• Measure the right leading indicators and the right results indicators by building a Rhythm dashboard of KPIs, which can be easily updated and visualized to provide the right level of visibility.
• Use Lean’s 8 Step Process to define problems and work on solutions as soon as issues are uncovered in your Weekly Adjustment Meeting. 

Rhythm and Lean Are Not Just Tools - They're Ways of Thinking

Both Rhythm and Lean have similar and complementary philosophies—ways of being mindful and intentional about making improvements. Neither philosophy works without people who are ready to embrace and implement them, so start by educating your team. Teach them the methods and processes, and seek external support if needed.

Not long ago, I visited another client who recently deployed Lean. The first time the Lean consultants came into the business, they taught the processes but did not teach the philosophy. The team had new tools, but they did not have a new way of thinking. Due to this gap, the company could not sustain the Lean methodology on their own, and they backslid into their old problems. 

They brought in a second team that focused on training employees on Lean philosophies, not just doing Lean. This team of consultants helped the employees grasp both the why and the how to successfully deploy Lean. Only when they did this could they achieve lasting improvements. Rhythm had already given them a disciplined structure of activities to run their business with consistency and accountability; the Lean philosophy strengthened their ability to solve problems and cut out waste.

Getting Your Business Into a Lean Rhythm

If you are searching for the best methodology for your business, remember the power of the A-N-D! You can incorporate elements of Rhythm and Lean into one smooth, efficient way of working. To do this successfully, start with why for both methodologies. As your team learns new tools and processes, make sure they are also adopting new mindsets. 

Create a cadence of strategically aligned activities with Rhythm, and then use Lean to drive even richer conversations and faster problem-solving.