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Topics: Change Management, Leadership, Talent Management
Lean production systems and Covid-19
We have had, worldwide, disruptions (breaks) in the supply of masks, disinfectants, other products and equipment necessary for the treatment of Covid-19

Now it is necessary to order, produce and supply the market with these products resulting in disruptions in supply chains.

To what extent are lean systems suitable in crisis situations?
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Lean processes are better in any contexts. Why encourage waste or if reduce customer value realization even when there is no sense of urgency?
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1 reply by Luis Branco
Mar 15, 2020 3:17 PM
Luis Branco
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Dear Kiron
Thank you for participating in this reflection and for your opinion

Interesting what you wrote: "Lean processes are better in any contexts. Why encourage waste or if reduce customer value realization even when there is no sense of urgency?"

In this situation, people are dying because there are no products and equipment
Mar 15, 2020 2:30 PM
Replying to Kiron Bondale
...
Lean processes are better in any contexts. Why encourage waste or if reduce customer value realization even when there is no sense of urgency?
Dear Kiron
Thank you for participating in this reflection and for your opinion

Interesting what you wrote: "Lean processes are better in any contexts. Why encourage waste or if reduce customer value realization even when there is no sense of urgency?"

In this situation, people are dying because there are no products and equipment
...
1 reply by Kiron Bondale
Mar 15, 2020 6:09 PM
Kiron Bondale
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Part of the challenge is the demand (legitimate or not) has vastly outstripped the supply and ramping up production by one or more orders of magnitude cannot usually be done easily when it comes to producing physical products.

If folks hadn't started by hoarding these products, there may have been more supplies available in the initial period to give factories sufficient time to ramp up their efforts.

Kiron
Mar 15, 2020 3:17 PM
Replying to Luis Branco
...
Dear Kiron
Thank you for participating in this reflection and for your opinion

Interesting what you wrote: "Lean processes are better in any contexts. Why encourage waste or if reduce customer value realization even when there is no sense of urgency?"

In this situation, people are dying because there are no products and equipment
Part of the challenge is the demand (legitimate or not) has vastly outstripped the supply and ramping up production by one or more orders of magnitude cannot usually be done easily when it comes to producing physical products.

If folks hadn't started by hoarding these products, there may have been more supplies available in the initial period to give factories sufficient time to ramp up their efforts.

Kiron
...
2 replies by Luis Branco and Stéphane Parent
Mar 16, 2020 8:26 AM
Luis Branco
...
Dear Kiron
Thank you for sharing your opinion with us

We agree that the development and application of Lean has reduced waste.
Kaizen will definitely help to improve this system

Should there be some sectors of activity in which this approach needs to be rethought?

Fact: stock-outs of health products and equipment

I did not refer to the breakdown of product stocks resulting from people's behavior (hoarding)
Mar 16, 2020 1:18 PM
Stéphane Parent
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I agree that stockpiling affects the demand vs. supply balance. On the other hand, stockpiling brings its own set of problems, including storage and spoilage.
Mar 15, 2020 6:09 PM
Replying to Kiron Bondale
...
Part of the challenge is the demand (legitimate or not) has vastly outstripped the supply and ramping up production by one or more orders of magnitude cannot usually be done easily when it comes to producing physical products.

If folks hadn't started by hoarding these products, there may have been more supplies available in the initial period to give factories sufficient time to ramp up their efforts.

Kiron
Dear Kiron
Thank you for sharing your opinion with us

We agree that the development and application of Lean has reduced waste.
Kaizen will definitely help to improve this system

Should there be some sectors of activity in which this approach needs to be rethought?

Fact: stock-outs of health products and equipment

I did not refer to the breakdown of product stocks resulting from people's behavior (hoarding)
Mar 15, 2020 6:09 PM
Replying to Kiron Bondale
...
Part of the challenge is the demand (legitimate or not) has vastly outstripped the supply and ramping up production by one or more orders of magnitude cannot usually be done easily when it comes to producing physical products.

If folks hadn't started by hoarding these products, there may have been more supplies available in the initial period to give factories sufficient time to ramp up their efforts.

Kiron
I agree that stockpiling affects the demand vs. supply balance. On the other hand, stockpiling brings its own set of problems, including storage and spoilage.
"Lean" production means producing just the right amount at the right time thus not creating any waste. It does not mean producing less than required resulting in shortages. The right amount should include for increased demands due to unplanned occurrences (risk events). Someone should have done the risk analysis and come up with mitigating measures should such a risk event occur. Two possible mitigating measures for product supply is 1) stockpiling, or 2) increased capacity to produce at a moments notice.
The only question that has to be asked during the planning stage is: what happens if? Answer - let people die (accept the risk) or implement mitigation measures.

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