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Lean Implementation
Applications and Hidden Costs
Sustainable Improvements in
Environment Safety and Health
Series Editor
Frances Alston
ESH Director
Lawrence Livermore National Laboratory, CA
The Legal Aspects of Industrial Hygiene and Safety, Kurt W. Dreger [2018]
by
Frances Alston
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
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Preface ......................................................................................................................xi
About the Author ................................................................................................ xiii
v
vi Contents
Lean thinking is a concept that is widely discussed and used on many levels
across various business processes. The application of Lean has been visible
in many industries, such as automotive, health care, and banking, and in
government. Lean in a sentence involves instituting practices that will
eliminate nonvalue added steps that will reduce waste and create value while
fostering a culture that is supportive of continuous improvement. The value
that is created can be beneficial to both the customer and the company. Lean
thinking and reengineered processes are helping companies to increase pro-
ductivity, meet and exceed their customer expectations, and improve their
financial goals.
Some practitioners refer to Lean as a process that affords an organization
the opportunity to “do more with less.” This essentially is true; often Lean
process improvement initiatives can result in staff reduction or reallocation
and changes in the company compliance posture, impact the ability to suc-
cessfully implement a succession planning strategy, limit knowledge trans-
fer and employee retention, and the list goes on. These impacts can be costly
to a company when balancing the changes that are required to keep these
processes optimized and address the people aspects of implementing Lean.
The impact and cost associated can be hidden if not addressed during the
upfront planning process.
The ability to successfully implement Lean requires that the culture
of the organization be open to adapting to changes in the new way that
business will be conducted. The lack of a culture that is supportive of
change has contributed to the failure of many attempts to implement
Lean process improvement initiatives. To successfully implement Lean
thinking within a company, a comprehensive strategy must be in place
that includes not only the reengineered process, but the people aspects
of the process. The strategy should include ways to address issues such
as the following:
xi
xii Preface
This book will address key organizational issues that must be considered
and addressed when implementing Lean business practices, offer solu-
tions for many of the challenges, provide a resource that leaders can use in
addressing cultural and regulatory issues, and provide a means to address
the associated people issues and the challenging task of knowledge retention
and succession planning. Vignettes are used to illustrate and provide exam-
ples of potential issues and solutions that can be considered for resolving
issues as well as identify key references that can be consulted for additional
information on key concepts. A case study is included that demonstrates
ways to address the technical and people aspects of implementing Lean to
ensure project success.
About the Author
Dr. Frances Alston has built a solid career foundation over the past 25 years
in leading the development of management and of environment, safety,
health and quality (ESH&Q) programs in diverse cultural environments.
Throughout her career, she has delivered superior performance in com-
plex, multistakeholder situations and has effectively dealt with challenging
safety, operational, programmatic, regulatory, and environmental issues.
She has been effective in facilitating the integration of ESH&Q programs
and policies as a core business function while leading a staff of business,
scientific, and technical professionals. She is skilled in providing technical
expertise in regulatory and compliance arenas as well as in determining nec-
essary and sufficient program requirements to ensure employee and public
safety, including environmental stewardship and sustainability. Dr. Alston
also has extensive knowledge and experience in assessing programs and
cultures to determine areas for improvement and development of strategy
for improvement.
She holds a BS degree in industrial hygiene and safety/chemistry, an
MS degree in hazardous and waste materials management/environmental
engineering, an MSE in systems engineering/engineering management,
and a PhD in industrial and systems engineering.
Dr. Alston is a fellow of the American Society for Engineering Management
(ASEM) and holds certifications as a Certified Hazardous Materials
Manager (CHMM) and a Professional Engineering Manager (PEM). Her
research interests include investigating and implementing ways to design
work cultures that facilitate trust.
xiii
1
Lean Thinking
1.1 Introduction
Many practitioners have argued the sustainability of Lean process improvement
in an organization. Some even believed it to be yet another fad or buzzword
that will dissipate with time. Lean process improvement initiatives are not
likely to be successful without being championed and supported by a Lean
thinking team that includes the leadership team and workers. Lean, simply
put, is a way of thinking followed by the right actions that guide the way in
which work is performed to improve business across the board in an efficient
and streamlined manner. The practices and procedures that support Lean
thinking must be ingrained in the culture and the mind of members of the
organization. Once Lean becomes ingrained in the minds of the leaders and
workers and is seen in their actions, the organization can move forward with
purpose and successfully implement a Lean business strategy. Lean thinking
is not a temporary state of mind or a way of thinking that can be turned off
and on at a whim. It requires a commitment to a physical condition as well as
long-term discipline. Lean is focused primarily on providing value for the cus-
tomer, eliminating waste, and continuously improving all facets of business
processes. The most important components that are critical to implementing
Lean are presented in Figure 1.1. These components will also be discussed in
some form throughout this chapter and this book.
Going Lean can be rigorous and draining on internal resources initially;
therefore, careful considerations along with a detailed strategy are necessary
to chart the way to success. Before beginning the journey to Lean, it is imper-
ative that top management is supportive and that support is demonstrated
through the words they speak and also through their actions. In addition, it
is necessary to ensure that the people, physical resources, and policies are in
place before moving forward.
Some would say that Lean offers an organization the ability to do more
with less; however, a more accurate depiction of Lean is that it offers the
ability to optimize processes and outcomes that yield a win–win environ-
ment for a company, its employees, and its customers. In doing so, often, the
1
2 Lean Implementation
Strategic
thinking
Flexible culture
Employee
engagement and
buy-in
Continuous
improvement
FIGURE 1.1
Lean process components.
TABLE 1.1
Overriding Lean Principles
Principles of Lean Functions
Determine the customer value Clearly defines the value for products and services that
the customer is expecting and targets all nonvalue-
added activities for removal from the process. These
activities represents system waste
Identify the value stream and The value stream consists of all of the activities that are a
then map part of producing the products or services delivered to
the customer. The knowledge gained from this process
helps determine what means will be used to deliver
what the customer is expecting
Focus on eliminating waste and Eliminating waste ensures efficient flow of products or
create flow services to the customer without interruptions. Waste
elimination is also another way to reduce cost
Respond to pull by customer Understanding what the customer wants and when they
expect delivery of products or services. Developing a
process to deliver
Pursue perfection to achieve Continuous improvement in creating flow, identifying,
continuous improvement and removing waste
These attributes not only provide the optimal operating environment for
Lean, they are also beneficial to other aspects of a business strategy. Each
of these attributes will be discussed in a little more detail in Sections 1.2.1
through 1.2.10. These attributes are not listed or discussed in order of prefer-
ence or priority.
When people feel respected, they are likely to respect the management team
and the company. The respect of workers will manifest itself in the way they
respond to the leadership team and the work they perform on behalf of the
organization.
G. W.
LETTER MCCCL.
To W―― P――, Esq.
G. W.
LETTER MCCCLI.
To Mr. and Mrs. D――n.
O glorious King,
Us thither bring
LETTER MCCCLII.
To Mr. R―― K――n.
My dear Friend,
S TILL I serve a God whose mercy endureth for ever. Mr. D――n
received us most gladly. As sweet a gospel excursion as at any
time. The Cambridge interview, I trust, was of God. I met, within
three miles of Norwich, with another clergyman of the
establishment, who promises well. He heard me last night. It was a
night of power: a large congregation. It will be too large, I fear, to-
morrow, though the place will hold some thousands. I expect to
preach twice in my way to town, which I hope to reach by Thursday
evening. But I fear my Spring and Summer inward fever is returning.
If so, my large intended plan of operations will be much contracted.
But future things belong to Him who orders all things well.
Remember me before his throne. Salute dear Mr. H――y, D――s,
and E――s (if come to town) and all enquiring friends, and accept
the same for your whole self, from, my dear friend,
G. W.
LETTER MCCCLIII.
To the Same.
My dear Friend,
M Y new horse failed the first night; but, through mercy, we got
here yesterday about seven in the evening. I was regaled with
the company of some simple-hearted, first-rate old Methodists, of
near thirty years standing. God willing, I am to preach to-morrow
morning, and to have a general sacrament on Friday evening.
Perhaps I may move after Sunday towards Wales; but must be
obliged, I fear, to take post-horses. I care not, so that I can ride post
to heaven. Hearty love to all that are posting thither, hoping myself
to arrive first. This tabernacle often groans under the weight of my
feeble labours. O when shall I be uncloathed! When, O my God, shall
I be cloathed upon! But I am a coward, and want to be housed
before the storm. It is nearer and nearer. Happy they who have fled
to Christ for refuge! I could enlarge, but have only time to send you
my most unfeigned thanks and most cordial love, as being, my very
dear Sir,
G. W.
LETTER MCCCLIV.
To Mrs. M――h.
G. W.
LETTER MCCCLV.
To Mr. and Mrs. S――n.
G. W.
LETTER MCCCLVI.
To Mr. R―― K――n.
My dear Friend,
G. W.
LETTER MCCCLVII.
To Mr. R―― K――n.
Haverford-west, May 31, 1767.
Y OUR spiritual mind medley was very agreeable. I could wish for a
second dose, but know not what direction to give about
sending it. My rout is not yet fixed. I am just come from my field
throne. Thousands and thousands attended by eight in the morning.
Life and light seemed to fly all around. On Tuesday, God willing, I am
to preach at Woodstock; on Friday, at Pembroke; here again next
Sunday by eight, and then for England. I wish dear Mr. H――y
present, to see the people:—but,—and there are so many other buts
in the way, that I would not press him. Mr. D――s is returned in
safety. I hope Mr. B――dge will not miss of his expected preferment.
Joab’s hand is in the G――h scheme. Rooms are not so lofty or
large, prospects not so pleasant, bedsteads not so easy, in these
parts, as in some places in or near London, but all good enough for
young and old pilgrims that have got good breath. Tender love to all.
Let all join in prayer for us. I have been pushing on dear sick Mr.
D――s, to go out and preach six miles off. He is gone finely
mounted, and I am persuaded will return in high spirits. Who knows,
who knows but preaching may be our grand catholicon again? This
is the good methodistical, thirty year old medicine. That you may live
to see it revived, and tried a thousand and a thousand times over, is
the hearty prayer of, my dear dear friend,
G. W.
LETTER MCCCLVIII.
To Mr. and Mrs. D――n.
Haverford-west, June 1, 1767.
G. W.
LETTER MCCCLIX.
To Mr. R―― K――n.
G. W.
LETTER MCCCLX.
London, July 21, 1767.
My dear Sir,
I HOPE, ere this comes to hand, you will have taken your second
degree. A good degree indeed: to be a preacher, a young
preacher, a mobbed, perhaps a stoned preacher—O what an honour!
How many prayers will you get when I read your letter at
Tabernacle; and the prayers of so many dear children of God will do
you no hurt, I assure you. When we are fighting with Amalek below,
it is good to have a Joshua praying for us above. Jesus is our Joshua,
Jesus is our intercessor; he liveth, he ever liveth to make
intercession, especially for his young soldiers. Yonder, yonder he sits:
whilst praying he reaches out a crown: at this distance you may see
written in capital letters, Vincenti dabo. All a gift, a free gift, though
purchased by his precious blood. Tell churchmen, tell meetingers, tell
the wounded, tell all of this: tell them when you are young; you may
not live to be old: tell them whilst you are an under graduate; you
may be dead, buried, glorified, before you take a college degree: tell
those who would have you spare yourself, that time is short, that
eternity is endless, that the Judge is before the door: but I can no
more,—the thought overwhelms: but with what? with joy, joy
unspeakable and full of glory. Good night! I long to hear particulars
from ――. If you send me word that young ―― is there, I will
answer his letter that hath lain by me some time. My poor prayers
await you all. God bless you! God bless you!
G. W.
LETTER MCCCLXI.
London, August 6, 1767.
My dear Sir,
If you write with all deference, let him know that Jesus hath revealed
himself not only to you by his word, but in you by his spirit: that you
look upon those whom he is pleased to term deluded and fanatics,
as the excellent ones upon the earth; and that you choose rather to
suffer reproach with them, than to enjoy all the pleasures of sense,
and all the preferments in the world. But why do I dictate? I trust
you to the teachings of that Jesus who hath said, “It shall be given
you in that hour what you shall say.” Where doth this ―― live? What
is the ―― he mentions? God grant it may be a nursery for what he
calls fanatics so long as one stone is left upon another. One letter
more I imagine will rid you of further trouble from this quarter;
expect then attacks from another: but look to Jesus; he will make
you more than conqueror. I thank thee, holy Father, Lord of heaven
and earth, that thou hast hid these things from the wise and
prudent, and revealed them unto babes. Even so, Father, for so it
seemeth good in thy sight. Why me, Lord? why me? A sense of this
distinguishing love will make you laugh at all that men or devils can
say of or do unto you. Good night. I must away and pray for you.
To-morrow Mr. ――, &c. breakfast with me. God bless you! Be of
good courage: give no way, no not for a moment.
G. W.
LETTER MCCCLXII.
To Mr. A――s.
I AM sorry to hear you have been sick. This hath been my case.
Blessed be God, I am better. Who knows but I may be
strengthened to take a trip to Scotland. This itch after itinerating, I
hope will never be cured till we come to heaven. Though laymen
occupy both the pulpits, at Tottenham-Court chapel and tabernacle,
congregations increase. “Not by might or by power, but by my spirit,
saith the Lord.” No weapon formed against Sion, shall or can
prosper. Our Thursday morning six o’clock tabernacle lecture is
crouded. I am looking for, and putting together old letters. Have you
any dated January or February 1743? Could you send to Mr. E――s
of Ebly, and enquire how Mrs. L――e may be directed to? Her
husband had many letters from me. How are dear Mrs. R――ts, and
Mrs. A――re? I never forget them in the midst of all my loves. I
hope you are surrounded with warm friends, a most kind and
affectionate nurse, and what is all in all, an infinitely compassionate
never-failing Jesus. To his unchangeable love I most earnestly
commend your whole self, and all dear never to be forgotten friends.
How is poor Mr. C――e? What an hospital is the church! Blessed be
God, there are no incurables in it however. Ere long, we shall be
where the inhabitants shall no more say, “I am sick.” Hallelujah. I
am, my very dear Tommy,
G. W.
LETTER MCCCLXIII.
London, August 26, 1767.
My dear Sir,
M R. ―― hath just now been with me, and shewed me your letter,
expecting also a sight of mine. But my letters are brought late,
and to-morrow I go to preach at Lady F――y S――y’s. I therefore,
though quite ill, must send you a few lines now. Go to Jesus; learn to
pray of the threatened apostles, viz. “And now, Lord, behold their
threatenings, &c. &c.” I am afraid they will only threaten. If an
expulsion should be permitted, it will take place, I believe, only for a
little time, and soon be repented of. Thousands of prayers were put
up for you last Monday, at tabernacle letter-day. The verses were
these:
Adieu.—
G. W.
LETTER MCCCLXIV.
To Mr. R―― K――n.
G. W.
LETTER MCCCLXV.
To Mr. R―― K――n.
G. W.
LETTER MCCCLXVI.
To Mr. R―― K――n.
My dear Friend,
G. W.
LETTER MCCCLXVII.
To Mr. and Mrs. S――n.
My dear Friends,
O glorious King,
Us thither bring,
G. W.
LETTER MCCCLXVIII.
To Mr. R―― K――n.
My dear Friend,
G. W.
LETTER MCCCLXIX.
To Mrs. H――.
My good Shunamite,
J UST as your letter came, I was taking pen in hand, to send you a
few lines. What a mercy, when good news comes from town and
country! And what news so good, as that of the word of the Lord
Jesus running and being glorified? This hath been the case with the
worthless, but willing pilgrim. Every where the sound of his blessed
Master’s feet hath been heard behind him. Field and street preaching
hath rather bettered, than hurt his bodily health. But as the weather
begins to break, he must look towards winter quarters. This makes it
impracticable for him to go to Madly. It is too far distant. May Jesus
support the suffering martyr. He will, he will!
I know this will find you a living martyr; a witness of the truths and
life of Jesus; the only preparative for dying a martyr. That whether
you live, you may live unto the Lord, or whether you die, you may
die unto the Lord, is the earnest prayer of, dear Mrs. H――e,
LETTER MCCCLXX.
To Mr. W――y.
H OW is death scattering his arrows all around us! even into our
houses. Perhaps, ere now, your dear yoke-fellow, as well as
dear Mr. Langworthy, and Mr. Wright’s mother, are laid in the silent
grave. Surely, the call to us is loud, yea very loud. Its language is
quite articulate. “Watch and pray, for ye know not at what day or
hour the Son of man cometh.” What is this world? nothing, less than
nothing. What is the other world? An eternity; an eternity of endless
misery or endless bliss. Lord Jesus, quicken our, at least my tardy
pace! I see more and more, that we have no time to trifle, to be
light, foolish, or worldly minded. A fever, a burning fever may come
with a commission to burn up our bodies. It spares neither Duke nor
Prince. Happy they, whom it finds burned up with the fever of divine
love. That living and dying, this may be your happy lot and frame, is
the hearty prayer of, dear Mr. W――y,
G. W.
LETTER MCCCLXXI.
To Mr. A――s.
G. W.
LETTER MCCCLXXII.
London, October 23, 1767.
My dear Sir,
B Y your brother Peter’s letter, the hour of expulsion is not yet
come. Surely they will not be so imprudent, or act so contrary
to the laws of English liberty. I long to know what statutes they say
you have broken, what concessions have been made. Your diocesan
will make a strict enquiry. I wish you could recollect all
circumstances; the rise and progress of the present contest; with all
the various pleadings, threats, conferences, pro and con. The issue
of the trial you may leave to the Judge; he is always the injured
prisoners friend. If confined to college, this will be a good exercise
for you. You may lodge it in court, as a proof whether you
understand to write plain English, or sound, practical, experimental
divinity. This can do you no harm; it may do good. Do therefore set
about it. I know one who will readily revile and correct, if necessary.
The Lord Jesus be with your spirits! You see how I write, out of the
fulness of my heart. Sick suffering soldiers must be attended. If ever
so busy, for the sake of the glorious Captain of our salvation, you
shall receive a line by way of answer from, my dear Sir,
G. W.
LETTER MCCCLXXIII.
To Mr. A――s.
G. W.
LETTER MCCCLXXIV.
To Mr. C――.
My dear Sir,
G. W.
LETTER MCCCLXXV.
To Mr. R―― K――n.
My dear Friend,
I WISH some one hour could be fixed for the triumvirate, to meet
once a week. Some business might then be done for both ends
of the town. Regular dispatch is beautiful. What your hand findeth to
do, do it with all your might, &c. I would settle every thing; perhaps
I may be called suddenly, as well as ――. Transporting thought!
Come, Lord Jesus, come quickly. I would reflect upon Wednesday
with humility and gratitude ¹. Lord, what am I? “Less than the least
of all,” must be my motto still. I hope you have got the better of
your pleasing fatigue. What an honour to do any thing for Jesus! in
Him, I am, my dear friend,
G. W.
My dear Sir,
G. W.
LETTER MCCCLXXVII.
To Mr. R―― K――n.
Tottenham-Court, November 27, 1767.
My dear Friend,
G. W.
LETTER MCCCLXXVIII.
London, December 1, 1767.
Dear Sir,
G. W.
P. S. Dear Mr. ―― must hear from me next. God bring all your
souls out of prison. Amen and amen.
LETTER MCCCLXXIX.
To the Hon. and Rev. Mr. S――y.
G. W.