Bringing Lean work organizationto the shopfloor across Europe

A large, internationally successful automotive manufacturer did not want to merely “introduce” Lean. The goal was to truly understand it, apply it and live it across all plants in Germany and Europe.

The key challenge was clear:
How do you qualify employees, supervisors and team leaders in a way that makes Lean natural rather than theoretical?

Together, we developed a Europe wide training concept that did not explain Lean, but made it tangible and experiential.

The focus was on shopfloor work organization, the first level of leadership and the teams that define the daily production rhythm.

We:

• developed a complete Lean training system

• designed training programs for employees, supervisors and team leaders

• conducted qualification campaigns across Europe

• used simulations to teach Lean in a hands on and engaging way

• rolled out Lean work organization in all plants

• enabled leaders to improve processes independently

• established a shared and consistent Lean method language

The core idea was simple:
Lean should not be complicated. Lean should be engaging, effective and make everyday work easier.

By using simulations and interactive formats, Lean principles became visible and understandable in daily work.

Teams experienced firsthand:

• how waiting times arise

• where handovers create friction

• how clarity stabilizes processes

• how collaboration across interfaces improves flow

• how much potential lies in their own daily work

This led to a decisive success factor:
A shared understanding of processes, value streams and the importance of collaboration across departmental boundaries.

By qualifying the first level of leadership, the people who make decisions, solve problems and set standards every day, a sustainable transformation emerged:

• Lean was understood with confidence

• work organization became firmly embedded

• processes were systematically improved

• leaders became self sufficient in Lean methods

• plants worked in a more aligned, structured and efficient way

• employees experienced improvement as something positive, not threatening

Lean evolved from a project into a core part of the company’s DNA.

Through the Europe wide rollout, a shared understanding emerged across countries and locations, creating a real competitive advantage.

Because it shows that Lean training does not have to be boring or theoretical.

When Lean is taught in a lively and practical way, people realize how much influence they have and start actively shaping processes instead of just following them.

This success story proves:
With the right training concept, it is possible to inspire thousands of employees for Lean and sustainably strengthen an entire organization.