u/_-reddit-_-user-_

I'm in a position where I'm going to be teaching my team One Piece Flow, and I'd like some advice from people who have done this before.

My thought is that I don't just want to tell operators, "This is One Piece Flow, do it this way." I want them to see the waste for themselves.

For example, I want them to recognize things like:

Excessive movement

Waiting

Batching

Excess WIP

Transportation

Rework

Other forms of waste they encounter in their own process

The goal is for them to become uncomfortable with the waste they're participating in and start asking, "Why are we doing it this way?"

My management wants us to approach this as a change-management exercise rather than simply rewriting the WI and telling everyone to follow a One Piece Flow process. They want the team convinced that the future state is actually better.

The One Piece Flow process appears to be faster, so I'm planning to establish a baseline of the current state, then demonstrate the future state and compare the results. I understand that I'll need to go through the current state → identify waste → develop future state → test/measure → standardize process.

Where I'm unsure is how to teach this effectively.

I've taught individuals before and have shown people how I try to get as close to One Piece Flow as possible. Most of the people I've worked with understood the concept and ended up applying it themselves.

But this is different. Now I have an entire department, and I also have a manager I need to get buy-in from.

For those of you who have implemented/taught One Piece Flow:

Would you approach it this way?

Would you have the operators map/observe the current process, identify the 8 wastes themselves, then run a timed comparison between the current state and a One Piece Flow future state?

Or am I overcomplicating this and approaching the change incorrectly?

I'm especially interested in how you got operators to want to change the process rather than simply comply with a new WI.