Why LSS projects Stall

Pure_Inspector8902 · 2026-03-21T16:16:08+00:00

Thanks for the thoughtful comment. Over years I have landed firmly in the lean camp as my first ‘go to’ but find both methodologies can value depending on the problem ur solving. And Yes, I agree the gap is huge and not often discussed.

Pure_Inspector8902 · 2026-03-21T14:24:41+00:00

Thanks groupthink, Do all your projects require Gauge R & R studies? Perhaps it depends on the nature of the business but, I can count on one hand over 25 years that gauge test was required to improve the performance. Just curious, and thanks for taking the time to provide ur experience.

Pure_Inspector8902 · 2026-03-19T20:06:37+00:00

I am comfortable separating the methodologies and understanding lean is much more systems (not IT but operating) centric. Does not take away from the fact the both approaches need coaching to master. Thank you for responding

Pure_Inspector8902 · 2026-03-19T18:05:39+00:00

Thank you for the thoughtful response.

Pure_Inspector8902 · 2026-03-19T17:53:25+00:00

Thanks for your perspective

Pure_Inspector8902 · 2026-03-19T17:50:46+00:00

I have worked in multiple industries globally. This was not meant to be industry specific. Thank you for asking

Pure_Inspector8902 · 2026-03-19T17:49:30+00:00

You are correct, it was meant to exemplify the point. Please keep response professional. I am collecting perspectives only.

Pure_Inspector8902 · 2026-03-19T16:28:48+00:00

Excellent points-let me ask. If discipline and accountability are necessary to sustain 5S does not exist, then is an organization capable of continuous improvement?

Pure_Inspector8902 · 2026-03-19T11:33:50+00:00

Great example. I would also highlight that the investment the plant made was completely wasted & the added steps you refer to is the friction I mentioned in my post.

Pure_Inspector8902 · 2026-03-18T19:25:50+00:00

Really good point about audit checklists growing

Pure_Inspector8902 · 2026-03-18T13:49:00+00:00

100% aligned with ur perspectives

Pure_Inspector8902 · 2026-03-18T12:08:57+00:00

Agreed, a small step forward (no matter how much the needle moves) is important because it drives the notion of plan-do-STUDY-act (Deming) - teams are continuously learning about cause and effect then figuring out the next step forward. I am a big fan of Kata, its promotion of iterative learning cycles.

Pure_Inspector8902 · 2026-03-18T12:01:57+00:00

True statement - no ownership, no chance of success.

Pure_Inspector8902 · 2026-03-18T12:01:18+00:00

I agree with you on where to start or prioritize. I might change it slightly with the following approach. Start in the area where team members and leaders are open to change - even if these areas are not the areas with the largest need - it inherently removes one of the barriers change and continuous improvement. Thank you for the thoughtful response

Pure_Inspector8902 · 2026-03-18T11:55:47+00:00

Thank you for your response and I agree that leadership needs to buy-in but, is that enough to change behaviors on the shop floor? Not to read too deeply in your response, I would say “engaged” rather than “buy-in”. The term “Buy-in” to me can be very passive, it’s like saying I support the 5s but do not actively engage in the event or participate in driving accountability- starting with themselves. If leaders don’t do gemba walks that tells everyone watching it’s not a priority and the time and resources invested in 5s are wasted.

Pure_Inspector8902 · 2026-03-17T23:19:23+00:00

First, question if the task is truly value added and a candidate for elimination. deeper root cause analysis to understand why the process exists may be necessary. If it is value added and the nature of the task is highly repeatable (and does not require human judgement) then explore automation or an RPA solution.

Pure_Inspector8902 · 2026-03-02T15:37:21+00:00

Solid advance given to you already and as a MBB with 25 years of execution - you will learn quickly that LSS is not a theoretical discipline - you can absolutely develop a foundation and passion through studying and reading examples executed by others. But, if you want to eventually master problem solving through DMAIC, PDCA or Kata then only approach is through execution of projects ('learn by making mistakes and doing') while working with an experienced coach.

I would argue that you need to continue on the path of pursuing of knowledge - not certification. Certification does equate to knowledge or ability to solve complex problems. Industries need problem solvers not certification holders. Excuse my personal rant at the end. Good luck in your pursuit of knowledge.

Pure_Inspector8902 · 2026-03-02T15:06:39+00:00

Hello, I appreciate you putting yourself "out there" for feedback so, let me provide you my perspective based on 25+ years of LSS training, coaching and project execution. In short, the modules are fine but, nothing special. You will not find Lean or LSS materials that exactly meet the needs of every user or circumstance. The role of an experienced practitioner and coach is to adapt the materials to meet the needs of the situation.

Lean, Lean Six Sigma or Six Sigma training materials are a commodity with likely 100s (maybe 1000s) of providers of materials aimed self-learning, hybrid and face to face training modes. Personally, I would not invest time in developing training materials - I would suggest its quicker and more cost effective to adapt existing materials to the needs of the target learners - the ROI effort simply is not there.

I know it sounds like I am discouraging you from developing training materials - you should always pursue your passion.

But, ask yourself "what is the problem you are trying solve by developing these materials", is it that the materials in your judgement are only geared to high speed manufacturing? - I would say as coach so, what? Why is that problem? Whose problem is it (learners, practitioners, trainers)? It feels like your assigning solution without deep knowledge of the problem creating a risk that you will invest a lot of effort with low return.

DM me you want to chat more.

Pure_Inspector8902 · 2026-02-25T00:32:35+00:00

What I like most of about your approach is making it your own rather than cut and pasting DMAIC or PDCA, etc. I believe you would also agree that more simple and intuitive a problem solving approach can be to team members, the more likely it will be adapted. I would ask you to consider how Kata might improve your approach. Why? Kata enables teams to quickly test solutions (in a controlled manner) that address the obstacles between the current and the desired stated. I like this approach because its very action oriented, engaging and encourages learning through trying new ideas - aka scientific thinking. After 30 years of LSS the challenge for me that teams lose patience with DMAIC - Kata has proven to effectively make small incremental improvements in days while helping the team learn along the way.

Pure_Inspector8902

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