Additionally, maintenance personnel are often so fully engrossed in their daily activities that it is quite difficult for them to find time for understanding "Lean" concepts let alone finding time to carry out the "Lean" implementations.
Facing the Challenge
So how do companies deal with the challenge of implementing "Lean" in maintenance processes? Well, the answer lies in the use of computerized maintenance management software (CMMS) systems that help in streamlining maintenance activities. CMMS systems help because they allow maintenance managers to reduce the average time spent on general maintenance activities, assess the average time lapsed between two consecutive maintenance tasks for all critical components, and identify the main causes of breakdowns.
All this automatically reduces the workload of maintenance personnel, giving them enough time to learn "Lean" concepts and methodologies and carry out the implementations.
How to Carry Out the Implementations
To improve the effectiveness and efficiency of maintenance services, it is necessary to make full use of the existing CMMS system during the Lean implementation phase. Lean implementations for maintenance services lead to better results when carried out under the CMMS framework because then it becomes easier both for the implementation team and the maintenance department to understand the technicalities involved.
Using a CMMS framework helps also because it allows access to critical information, some of which are described below.
-The average downtime of all equipment, critical to the main maintenance process selected for "Lean" improvements
-The root cause responsible for each downtime event
-An up-to-date list of all the present and proposed maintenance works and activities
-An up-to-date list of pending maintenance tasks
-The current ratio of total scheduled tasks to total maintenance work orders
CMMS is certainly necessary, but small businesses that may not have the financial muscle to deploy such systems, can opt for a manual system, similar to CMMS. A manual maintenance management system will certainly act as an obstacle for a large organization, but for smaller organizations, it is always better to have one, especially when "Lean" concepts are being implemented.
Apart from using CMMS, organizations should also provide the requisite training and support to the implementation team as well as the maintenance personnel. Lean concepts and methodologies are quite confusing, and if proper training and guidance is not provided, it will become quite difficult for the implementers to do justice to their implementation goals and objectives.
In the worst-case scenario, the whole "Lean" implementation project might get shelved due to the inability of the implementation team to complete the implementations within the planned costs and time. Training is thus as vital as CMMS while implementing "Lean" in maintenance processes.
Lean Six Sigma For Service
In addition, success stories of innovators and industry leaders prove that this methodology is not only effective but also helpful in providing practice guidelines for employing Lean Six Sigma in sales operations.
Selecting an Appropriate Project Focus Area
Many organizations are clueless about applying Lean Six Sigma principles and ascertaining the right type of project for sales operations. Based on experience and best practices of companies like Xerox, Honeywell, Johnson & Johnson, GE, and others, six types of projects signify the productivity for early projects.
1. Generation of Leads
2. Sales proposal procedures
3. Sales predictions
4. Launch of New products
5. Effectiveness and efficiency of the sales force
6. VOC, or Voice of the customer
These project areas can be classified into two types or categories. The first four project areas are included in Category 1. These project areas primarily concentrate on improving sub-processes in favor of or related to field sales. Very often companies find it easy to begin with Category-1 projects, as they are easy to map, identify, and visualize. Moreover, metrics and data based on the process performance are easy to gather and classify. The processes included are can be repeated in a coherent manner.
Although Category 1 projects create improvements in the effectiveness of internal processes, they may not be able to solely produce revolutionary results that attribute Lean Six Sigma initiatives. The projects included in Category 2 are much more capable of generating revolutionary results as they are considerably more challenging and complex when it comes to gathering dependable quantitative data, distinguishing reliable processes, gauging root causes, and employing solutions.
Nonetheless, since Category 2 projects have a greater impact on selling processes directly and the field sales force, they bring about resolutions and enhancements that make marginal growth and sustainable and significant revenue.
Sales Force Efficiency and Effectiveness (SFE&E) Projects
Companies with sales forces that call upon numerous customers and signify standard services and products are appropriate contenders for sales force efficiency and effectiveness (SFE&E) projects. These companies usually deal with hospital products and medical devices, pharmaceutical, information technology, and, financial services.
Even though sales representatives working for these companies have approximately the same customer and market opportunities when it comes to competition, products to sell, local territories, etc., there is a sizeable difference in the functioning and end results of every representative.
In Six Sigma language, if a considerable amount of process variation is eradicated, it will result in a revolutionary improvement in the income.
Voice of the Customer Projects
Voices of the Customer (VOC) projects are usually favorable to companies that have a strong customer segment and market. These companies function in industries like automotive, household appliances and aerospace, and have a small, consultative sales force, that is systematized around a few key accounts. The projects are aimed at dynamic market penetration or customer share by identifying every customer requirements.
These requirements could include measurable standard of products, relationship and service quality that a supplier should achieve for remain continuing business with an account holder. Certainly, meeting these requirements is not sufficient for ensuring continued customer share growth and sales, particularly in view of the fact that competitors in the same account could similarly try to increase customer share.
Lastly, Lean Six Sigma in sales projects should concentrate on growing profitability by running the topmost line of the business, rather than slashing expenses. As the profits escalate, the cost-to-revenue ratios and productivity of the sales force will also improve.
Tony Jacowski has sinced written about articles on various topics from University, Six Sigma and Information Technology. Tony Jacowski is a quality analyst for The MBA Journal. Aveta Solution's Six Sigma Online offers online and certification classes for lean six sigm. Tony Jacowski's top article generates over 90500 views. to your Favourites.
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