The Correct Way to Implement Lean [Part-3] - Change Management

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Change management must be considered as a part of the lean implementation in the apparel industry.

In the Part 1 and Part 2 of the correct way to lean implementation, I had covered why the pursuit of excellence through lean is difficult and corporate culture. In the 3rd part, I will discuss change management in the organization level.



I will discuss the following points to emphasise the improtance of bringing change and the change management.
  • The law of mind 
  • Difference forces that contrl our mind and thinking 
  • Solution to change menagement 
  • When we talk about change - what to change and making the chane happen 
  • How one can begin the change 

The Law of Mind

  • If you always do what you have always done, you will get what you have always gotten.  
  • If you want something new, do something new, especially when there are so many alternatives 
  • To keep pace with the changing environment, every organization has to bring change in its way of thinking, feeling and working
Yesterday
Today
Natural resources defined power
Knowledge is power
Leaders commanded and controlled
Leaders empower and coach
Shareholders came first
Costumers come first
Production determined availability
Quality determines demand
Everyone was competitor
Everyone is customer
Value was extra
Value is everything

Had a great past? 

You might have a great past but can it guarantee a great future also. The forces which forcing you to change to maintain your great past includes -

External forces:
  • Globalization 
  • Competition 
  • Customer demands 
  • Rising prices of inputs 
  • Technology 
  • E-commerce 
Internal forces:
  • Increasing complexity 
  • Demand speed 
  • Quick decisions 
  • Aging technology 
  • Employee expectations 
  • Profit margins 
  • Traditional systems 
What is solution?
Solution is change management.
  • What to change – identify the problems 
  • What should be the content of change – develop solutions 
  • How to make change happen – implement the solution 
  • How to sustain the change – transform your culture 


What to change?
Improvements can be made only through Change Management. There are four essential steps to bring permanent change.

To bring change in performance of any process or system we have to change the casual factors such as inputs, resources, activities, tasks, operating conditions etc.

To make improvement the very first step is to identify: “what to change?”

It is a diagnostic journey to discover the constraints or problems, which are restricting the desired outcome from the processes.

Problem diagnosis


The real problems are generally invisible. What we see is the effect of problems in form of symptoms. We can reach to the true problem through its symptoms only. (Here lean tool 5 why works which will be explained in upcoming parts)

Mostly people define the problems based on their experiences or instructions of their seniors. To detect the real problem we require scientific and effective tools such as
  • Business process waste assessment 
  • Cost of poor quality assessment etc.

What should be the content of change?
After identification of problem, the next step is developing solutions.

Detailed investigation of the problems (project-by-project) to detect the root cause, which need to be eliminated to solve the problem. (Here lean tool Root Cause Analysis works which will be explained in upcoming chapters)

Making the change happen
Problem solving tools are used to develop solutions.
Change is made through implementing the solutions

Implementations tools
  • Project teams 
  • Action plan 
  • Education and training 
Sustaining the change
Resistance to change is the most common human nature. Unless people’s resistance to change is overcome, there cannot be gain of the change.
  • Sustenance tools 
  • Empowerment 
  • Cultural transformation 
How to begin the change?
The very first step is - Change the way of thinking.

About the Author
Zakir Husain is an industrial engineer and a lean practitioner. He worked as a project manager in lean implementation projects. He has successfully implemented the online finishing system in an apparel manufacturing company. Currently, he is working at Richa & Company and doing projects on improving sampling and pre-production activities to maximize PCD hit rate.
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Online Clothing Study: The Correct Way to Implement Lean [Part-3] - Change Management
The Correct Way to Implement Lean [Part-3] - Change Management
Change management must be considered as a part of the lean implementation in the apparel industry.
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