Transform Your Business Strategy Today

It's the age-old question - when should a business take the plunge into the world of Lean, and how do you even start that wild journey?

You've got your Lean enthusiasts, the consultants, the trainers - they'll tell you, "Implement Lean now, do it top to bottom, company-wide! Make it rain with Lean!" But hold on a minute, from my adventures, that's not always the magical formula.

Picture this: you're trying to turn a factory around, and it's as challenging as convincing a Mexican Factory to break into a tap dance. But fear not, with a bit of grit and a step-by-step game plan, you can achieve miraculous transformations in record time, much like teaching that factory a few dance moves.

Now, when we chat about implementing Lean, we're talking about slimming down the waste by setting up super-efficient business processes, making everyday tasks as predictable as your morning coffee order, and becoming problem-solving ninjas who just can't stop learning and improving. Sounds great, right? Ideally, these should be on your radar from day one of your business venture.

But let's not kid ourselves; when you're running a small startup, it's all hands-on deck, and the focus is on perfecting your product, shouting about it to the world, and keeping your cash flow from doing a disappearing act. Formal business processes? You're lucky if you can even spell 'em. Small teams are a jack-of-all-trades bunch, and your Lean library remains mostly untouched.

So, where do we draw the Lean line? Well, consider this: as your business grows, things get a bit messy, a little complicated, like trying to solve a Rubik's Cube with one eye closed. Typically, it's when your monthly revenue starts flirting with the $300K to $700K range, and your staff count sits between 15 and 30.

At this point, it's tempting to throw in some new bosses and whip out the latest business management software to automate your way to glory. But the truth is, unless you clean up those processes first, all you get are more bills and more confusion. It's like trying to juggle flaming swords while riding a unicycle without learning to juggle or ride first!

What usually happens is:

• You're fighting daily fires, so you've got no time for innovation, strategy, or product development.
• Mistakes start creeping in, like late deliveries, quality hiccups, and poorly planned product launches, making customers give you the stink eye.
• Your costs are having a party while your revenue sulks in the corner. The fancy term for this mess is "dis-economies of scale."

And many businesses don't make it past this stage. They hang around for a while, but eventually, they fold or shrink like an ice cream cone in July. High costs, crummy processes, and more inventory than you can shake a stick at can lead to a swift cash crisis.  Funny how things flip, right? At this stage, no matter how awesome your product and marketing are, if you can't deliver on your promises in time, at top-notch quality, and without breaking the bank, you're kind of stuck.

So, the million-dollar question is when to unleash the Lean beast. You might hear people saying they're "not ready for Lean," but let's face it, that's like saying your kitchen's too messy to start cooking. It's a bit backwards.

There's a couple of good reasons to wait, though. If you're planning major leadership changes (like hiring a new Plant Manager), it might be smarter to let the new blood settle in before diving into Lean. In smaller outfits, don't bite off more than you can chew. A couple of projects at a time is usually the sweet spot. And guess what? Lean should be on that list because it can turbocharge your business like a nitrous oxide injection in a race car.

But where do you start this wild Lean ride? First things first, figure out why you need Lean in the first place. Is it to improve delivery, speed up lead times, boost quality, slash costs, or all of the above? Once you're clear on the "why," set your sights on the most critical value stream - the bread and butter of your problems. Map it out, reveal its secrets, and start the Lean magic there.

As for pilots versus going all-in, that's a bit like deciding if you should dip your toes or cannonball into the pool. For medium to large businesses, a pilot project can be a smart move. It lets you tailor Lean to your unique needs and builds your team's confidence. A full-scale dive into Lean, while tempting, can be costly, risky, and slower than a sloth on a coffee break.

So, there you have it, the Lean journey's starting line. Just remember, Lean isn't a magic wand, but when done right, it can turn a mess into a masterpiece, like turning a broken-down car into a sleek Ferrari. Buckle up, and let the Lean adventure begin!