Lessons from practice

Success factors for operational excellence

What helps an operational-excellence programme succeed? Experience from different programmes translated into an approach supported by your organisation.

Start with executive commitment

Ensure the programme has the support of senior management. A shared framework makes clear why the organisation wants to change, which goals provide direction and who takes responsibility. An improvement culture requires visible commitment, time and attention to implementation.

Senior management connects ambitions with daily operations. It creates room for observation, problem solving and coaching, and reviews progress itself. This keeps operational excellence part of how the organisation is led.

Develop Lean ambassadors

Lean ambassadors connect plant management, leaders and operators with daily application. They help develop a shared language and support colleagues in recognising and addressing improvement opportunities.

Training, coaching and follow-up make deviations open for discussion. The aim is for teams to carry out improvements themselves and share their knowledge further.

Start with a clearly defined pilot project

Choose one project with clear boundaries and a recognisable problem. Define the starting point, the goal and responsibilities. This allows the team to investigate which adjustment works and what implementation requires.

Share the first demonstrable results with the rest of the organisation. Also discuss what did not yet work. This experience helps select new improvement projects and prevents an approach from being copied without investigation.

Lean Leadership and presence on the shop floor

Gemba means looking where the work actually happens. Leaders listen, observe and ask questions before proposing a solution. Their presence helps connect daily reality with the chosen direction.

Lead by example: leaders demonstrate the behaviour they ask of their teams. They follow up agreements, investigate causes and make time to coach others.

Celebrate successes and share what you learn

Regularly recognise achieved results and the contributions of the people involved. Describe concretely what changed, how that became visible and what the team learned.

Sharing successes supports involvement and makes progress recognisable. Connect this with continued follow-up so an initial result can develop into a lasting way of working.

Measure progress with clear definitions

Choose indicators that fit the operational question and define the measurement basis. Productivity, safety, delivery reliability and quality costs each tell a different part of the story.

Assess indicators separately and in context. Discuss with the team which change lies behind a figure and what still needs attention. Results support learning and decisions; they do not provide a general guarantee for other assignments.

Embed the new way of working in your organisation

Make the improved way of working understandable and ensure ownership, knowledge transfer and a suitable review rhythm. Teams need to recognise deviations and know how to discuss them.

A shared framework helps learning and scaling. Local circumstances determine how teams apply that framework. The goal is for the organisation to continue improving independently.

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