An easy recipe for a lean transformation

Mike Wroblewski, Batesville Casket Company; lean sensei, Batesville Casket Company
Tags: lean manufacturing

Quick and easy lean transformation! It’s really good plain or topped with dark chocolate. My consultant friend makes a lot of bread using this deceptively simple recipe. Try this out at your food plant.

1 small company

2 cups all-purpose value stream maps (1 current state and 1 future state)
5 teaspoons small U-shaped work cells
2 dozen kanbans
9-minute SMED, or less if possible
Sprinkle of hour-by-hour charts
1 whole change agent (thick-skinned is best)
Heavy dose of kaizen events
2 pairs of value stream managers
Dash of standard work charts (add as much as needed to get desired taste)
1 ounce preventive maintenance

Baking Instructions
1. Preheat oven to 350 degrees (use broil setting if you need it quickly).
2. In a large bowl, mix all ingredients in any order, but it is recommended to add the value stream maps first to provide a solid dough base.
3. Beat all until a well-blended, smooth mix.
Note: You may have to remove hardened parts that do not blend easy.
4. Bake 2-3 years or until rising to world-class level.
5. Check often to prevent burning.
6. Let stand on cooling rack before eating.

Important disclaimer: Following all these instructions does not guarantee the end result will look anything like what is pictured on the box.

4 Stars – “I know this will sound a bit like a cliché, but I have been looking for a good lean transformation recipe my whole manufacturing career. I never imagined that I would find the perfect recipe until I tried this recipe. The company turned out crisp and lean with just right amount of filling, not a drop of waste. I will hand down this recipe for generations of management to come.”

5 Stars – “YUMMY! The easiest, best-tasting lean transformation I’ve ever tried.”

1 Star – “Awful recipe. My first batch failed to rise and left a lingering bad taste in my mouth. The trick may be to make sure the dough is well mixed with no concrete-like hard parts remaining. If the batch is not mixed with the right amount of ingredients, the batch easily crumbles and falls apart.”

Wouldn’t it be nice if there was an easy recipe like this for our lean transformation?

About the author:
Mike Wroblewski started his lean journey with instruction in quick die change from Shigeo Shingo. Mike is currently the lean sensei at Batesville Casket Company in Batesville, Ind.