T: Traditional Thinker
L: Lean Thinker
T: We cannot do X?
T: Because of Y
L: Let us find out why there is Y then we can try to do X
T: We cannot produce in small lot
T: Because the set up time takes long time and it is loss of production
O: Because it needs time
T: Yes, Why?
O: …. umm
T: So, let us go and see why it take long time, then we can find how we can make this time shorter
T: We cannot have small work in process
T: To ensure that equipment will not stop
L: Why do we need WIP to keep equipment running?
T: In case of troubles or bad quality
L: Why we have bad quality of troubles?
T: Many reasons….
L: Let us analyze them, prioritize them and then work on eliminating the major ones. After that we can decrease WIP
T: We cannot purchase in small lot
T: Because ordering and transportation costs will be higher
T: In every order and batch we pay fixed cost
L: Let us find out how to purchase in small lot without paying more
In traditional thinking, we stop at the first “Why?”, while in lean thinking we go deeper.
In traditional thinking, we react to causes, while in lean thinking we try to eliminate the causes.
In traditional thinking, we improve in how we live with the problem, while in lean thinking we improve by solving the problem.
In traditional thinking we assume there is no other way, while in lean thinking we believe we can find another way.