Most deployment failures to implement effectively Lean management are due to inability to conceive and manage a total change program :
- Top management lacks a sufficient understanding or vision
- Lack of well-orchestrated program
- No critical mass of lean skills and capabilities developed
- Transitional issues without adequate safeguards overwhelm organization
- Management reluctant to empower teams
- Middle management naysayers
- Unstable operations
- Difficulty of unlearning
- Current systems (i.e MRPII) and performance metrics (i.e labor efficiency) hinder progress
- Even after conceptual buy-in, managers do not know where to start Monday morning
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