Leanmap Knowledge Transfer

Closing Knowledge-Gaps

Continuous learning and continuous improving capability allows people to achieve challenging targets and maintain competitiveness of the business.

Problems – symptoms of knowledge-gaps

• Eroding knowledge, shrinking margin, losing competitiveness and market-share.
• Past successes can’t be repeated, old products are repackaged as “new releases”
• People work hard, have a “can do” attitude, but scrambling to meet targets
• Long hours, overtime, stress, and high turnover are "normal", burned-out employees leave
• Excessive multitasking, jumping from one to another job based on latest emergency

Reasons – root-causes of system issues

• Knowledge is concentrated around a few individuals, controlling information to maintain power
• Reactive organization, lack of skill and knowledge in proper planning and execution
• Accepting orders without understanding true cost, true impact, true capability, and true capacity
• Outdated know-how and technology make the operation slow, ineffective, and vulnerable

Solutions – closing performance-gaps

• Lean Transformation Program (LTP) › learning how to reduce waste and speed-up processes
• Radical Redesign (RRD) › learning how to create effective designs while minimizing parts/steps
• Cost Reduction Program (CRP) › learning how to reduce cost effectively and keep cost down
• Six Sigma Certification Black Belt / Green Belt › building quality-improvement skills
• Operations Diagnostics (OPD) › assessing capabilities of people, processes, systems
• Guided Plant Tour (GPT) › assisting managers in assessment, learning, coaching tours
• Workplace Organization (5S) › learning how to apply organizational principles to factory/office
• Innovative Product Development (IPD) › learning improving the success-rate of initial designs

Metrics – how success is measured

• Quality - applied learning creates consistent and predictable output at higher yield
• Speed - applied learning reduces cycle-time and response-time
• Participation - people are more engaged as they can influence their work

Duration – how fast to see results

• Workshop: 1+ weeks (5+ days) analysis and design > result: agreed system structure 
• Workout: 1+ months (20+ days) from analysis to implementation > result: functional system
• Duration depends on scope/size/complexity: forecasting = 1mth, ERP-integration = 6-12 mths

Bottom-Line – when knowledge-transfer is effective

• New knowledge translates into gains only when learnings are actually applied
• Returns within a year are typically 5-10x higher than the cost for training
• Training programs are effective when knowledge-gaps keeps performance low
• Requirements are: being aware of gaps and committed management to close them 

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