I have remembered how I have been amazed by a discovery in my own country Indonesia. I have gone so long to my reflective side of me after I have witnessed things that I couldn’t imagine to be exist in my country. Considering about the status of my country which categorized as a developing countries and the experience that I have on visiting several factories, I have been startled by a visitation to a factory in which the culture of Lean is very apparent.
In April 2011, I accompanied colleague students of my University to have a field trip to the automotive manufacturer plant which handle the assembly of medium and low trucks. I have had an experience for six months of internship in a quite famous automotive manufacturer overseas in Germany. Therefore, I presumed that the plant that we were going to visit was not possible to have a better management and/or technology than in Germany.
By the time we got there, I verify my assumption with the fact. It turns out at the first sight this plant which located in my country have nothing extra worth to be noted as better when compared to the technology with what the Germans have. It was a very conventional plant. At the site, we gathered together to a short briefing and quickly we were divided into several group and being arranged into route of travel around factory.
We make a start to the first process and go until the latest process in the plant. The tour guide which happens to be the supervisor and a foreman assisting us and generously share their experience about the working procedure, process, and experience. The workers in some areas are very kindly and proudly explaining the things that they are responsible of. I was astonished after we have come to an end. It was amazing to be there that day and I felt very fortunate to be there.
I saw that lean management in the factory that actually work. In that moment I totally changed my paradigm when I see with my own eyes that there is a factory runs smoothly by using no automation and high-tech and rely on the management of lean. They are many of lean concept use to manage the system. By concept I didn’t mean just methodology, but people actions and the the artifact of boards that daily updated, and the acknowledgement of suggestion of workers for all factory members. Besides of the Japanese auditor from Japan that always came to the factory to maintain the performance, many interesting facts have surprised me.
Previously I am very disappointed with labor from my country. It is because in my view, labor in my country is lazy and unproductive. However, what I saw that day at the factory could really make me realize the power of Lean. Lean could changed people behavior and culture to the desired one. I felt really happy to be there.