The initial Lean deployment in this organisation followed the classic model of top down deployment of Continuous Improvement leaders at a site level. This organisational structure also included the non-manufacturing areas.

Several surveys and feedback sessions had identified a “middle management gap” of Lean leadership. Middle and senior leaders were not actively supporting the Lean deployment. They were not aware nor had the skills to lead and deliver Lean management.

To design a compact, high velocity experiential training programme for the senior leaders in the business.

A staged programme was created covering production, business process and the people side of Lean. This involved running live value stream and business process kaizens alongside the training to maximise the learning experience. All the senior leadership of the organisation attended these workshops.

The workshops made a step change in Lean deployment across the business and accelerated the deployment of Lean and hence benefits.