Admin's blog

The 5 Biggest Continuous Improvement Challenges and How the Factory Operating System Solves Them All

1. Resistance from the Shop Floor and middle managers
As any Lean or Continuous Improvement (CI) practitioner can attest to, the first problem you encounter while trying to drive changes is resistance from the shop floor – and then the management team. The resistance is often created by a fear of change and people being pushed out of their comfort zones. It also arises from conflicting agendas.

New Booklet: The fOS - A Guide to World-Class Execution for American Manufacturers

As any manufacturing leader who has attempted to implement Lean, Six Sigma, Agile Manufacturing or any other Continuous Improvement initiative can tell you, it's not quite as "plug and play" as it seems in all the books and websites. It's now being estimated that as many as 70% of American Continuous Improvement initiatives fail. This video provides some insight to this phenomena and sheds some light on some of the prevailing reasons:

Whitepaper: Why Most American Continuous Improvement Initiatives Fail

It has been estimated that 70% of Continuous Improvement efforts such as Lean, Six Sigma, Agile Manufacturing and others fail to meet expectations. This happens for two primary reasons:

1) The Factory’s Operating Systems lack sufficient structure and are not conducive for Continuous Improvement. The Operating System is the array of policies, processes, people, and technology that are used to execute operations.

2) CI requires a high degree of Operational Discipline that, in the absence of a well-structured Operating System, is nearly impossible to cultivate.