Meeting/Event Information

Ten Ways to Mess Up Lean Implementation

September 20, 2017
5:45 PM to 9:00 PM
 Add to Calendar

Newlands Golf & Country Club
21025 48th Avenue
Langley, BC V3A 3M3


Who doesn’t have a story to tell about a lean implementation that went sideways? No outcomes. Business as it was after six months. 5S Audit sheets that haven’t been updated for three months. Worst of all, no improvement in customer service, throughput or profits.

If you’ve lived through this, you know how hard it can be to get any enthusiasm for another try. In this entertaining presentation you’ll hear about ten common ways that people inadvertently condemn lean efforts to failure. 

Some of the reasons are things you’ll expect. 

  1. No commitment from the top
  2. Trying to do it on your own
  3. Having the leader do it off the side of her desk
  4. Having a lean leader work solo
  5. Getting some wins and laying off the freed-up people 

But some will probably surprise you.

  1. Starting with 5S
  2. Learning the tools
  3. Using Lean everywhere
  4. Training everyone
  5. Looking for a big win early

Fortunately, not all is lost. We don’t need to throw out LEAN thinking. We just need to understand what LEAN thinking really is. At the end of the session, you’ll know about four practices that will get you started on the journey. And you’ll have some ideas about how you can give LEAN another try in your world.

Our Guest Speaker

Hugh Alley is an experienced operations manager with broad experience. He has achieved significant operational improvements in a wide range of industries. Examples include a 30% gain in productivity in a medical service company, a 50% gain in a quality index in an industrial service company, 10% a year increase in labour productivity in a metal manufacturing plant for three years in a row, a 95% reduction in lost time accidents in two years, a 10% gain in capacity in ten weeks for a heavy industrial manufacturer, and identifying an opportunity for a 50% increase in capacity with the existing facility for a logistics company. One company went from no suggestions from staff to implementing 1-2 per week in just three years. Hugh has run three different factories, and consulted for dozens more across Canada and the US. 

Hugh has worked in a wide range of industries including mining, steel, secondary wood, food, electronics and appliance assembly, heavy and light metal fabrication, repair and maintenance, industrial laundries, furniture, banking and others. He has also worked extensively in the public sector, including WCB, education, health care and various regulatory and permitting agencies.

For several years Hugh ran his own management development firm focusing on front line supervisors and leaders, and trained over 900 front-line managers. Most participants were able to achieve significant improvements in their area in the course of the programs.

He gets very excited when his students realize that they can make a difference in the working lives of the people that they oversee.

In addition to his operational roles, Hugh is an accomplished project manager. He ran four multi-million dollar projects that delivered as promised. He has also led three project rescues, in each case, getting the project back on track and preventing any further losses in time or money. Someone who builds consensus and encourages collaboration, Hugh is able to bring teams together. One IT director commented that he was amazed that in just two months, Hugh had moved a previously fractious project team from an attitude of blaming to one of problem solving. 

Now doing contract work, Hugh looks for opportunities where his analytical skills, his deep expertise in lean and his ability to develop people will let him make a difference in the workplace.

A registered industrial engineer, Hugh writes a regular column for PLANT magazine.


$40.00 Non-members
$45.00 after 12:00 am September 13

$20.00 Students
$25.00 after 12:00 am September 13

$35.00 Members
$40.00 after 12:00 am September 13