Transforming Manufacturing Incrementally
Christopher Turner 
Transforming Manufacturing Through the Power of Tiny Gains
As a Lean Transformation Consultant, one of the biggest challenges I face is helping manufacturing clients understand the power of making small, incremental improvements over time. Many companies want to see massive, disruptive changes that will completely overhaul their operations overnight. However, experience has shown that an iterative approach of continual small improvements is far more effective and sustainable.
To illustrate this concept, I use a brilliant image from James Clear's book - Atomic Habits, which is titled "The Power of Tiny Gains." This image depicts the compounding effect of improving by just 1% each day over the course of a year. The visual makes it strikingly clear how small, consistent changes can lead to tremendous outcomes.
At the start of the year, there is just a 1% gain. Not very impressive on its own. But when that 1% improvement compounds day after day, week after week, the results become remarkable. After one full year or 365 days, you have improved by 37 times the original 1% gain!
This concept is incredibly powerful for manufacturing companies looking to transform using a Lean methodology. Lean is all about eliminating waste and optimizing processes through continuous improvement. Instead of attempting disruptive, large-scale changes that are difficult to implement and sustain, Lean encourages companies to adopt the Japanese concept of Kaizen, which means to identify tiny areas for incremental optimization each day.
These small Lean improvements might include:
- Reducing movement/transportation waste by 1% through better workplace organization
- Improving process cycle times by 1% by eliminating redundant steps
- Decreasing inventory costs by 1% through pull and/or cross-functional coordination
- Cutting equipment downtime by 1% with better preventative maintenance
On their own, these 1% improvements don't seem like much. But when compounded over weeks, months, and years, the results are tremendous. A 1% improvement in process cycle times, inventory costs, and equipment downtime can combine to deliver incredible gains in manufacturing throughput and profitability.
The key is developing a corporate culture of continuous improvement and employee engagement. Workers at all levels must be trained on Lean principles and empowered to identify areas for incremental optimization each day. An attitude of "That's how we've always done it" must be replaced by a hunger for Kaizen, the Japanese philosophy of continual improvement.
The Power of Tiny Gains image resonates because it shows in a straightforward, visual way how small steps can lead to exponential growth when sustained over time. For manufacturers, pursuing an iterative Lean transformation through 1% daily improvements allows companies to continually optimize without disrupting operations. Consistent tiny gains in productivity, quality, and efficiency can compound into a powerful competitive advantage.
Categories: : Training