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Writer's pictureRaimund Laqua

When Getting Lean Puts You at Risk: A Cautionary Tale

In my 30+ years working with organizations on their transformation journeys, I've noticed a concerning trend that keeps me up at night. While companies rush to embrace Lean methodologies - and they absolutely should - many are inadvertently creating serious vulnerabilities in their pursuit of efficiency. Let me explain why this matters to you.


The Efficiency Trap


Picture this: Your team is deep into a value stream mapping exercise. Everyone's excited about identifying "waste" and streamlining operations. Someone points to a series of checks and approvals in your process. "Look at all these non-value-adding steps!" they exclaim. The room nods in agreement.


But here's the thing - not all "inefficiencies" are created equal.


The Hidden Value of Controls


Those seemingly redundant checks? That "bureaucratic" approval process? They might actually be critical controls put in place after hard-learned lessons. The problem is, institutional memory fades. What was once a crucial safeguard becomes "just the way we've always done it" - until it's not.


Think of it like removing what looks like redundant code from a critical system. Sure, it might make your code cleaner, but what if that "redundancy" was actually a crucial fail-safe?


We would also never remove code just because we don't understand what it does? However, this happens more often than many care to admit in the name of "cost reductions."


Real-World Consequences


In my work across highly regulated, high-risk sectors, I've observed a concerning trend where the enthusiasm for Lean methodologies sometimes overshadows critical safety, security, quality, and regulatory considerations.


Incidents of LEAN Teams value streaming management processes have eliminated what they viewed as "redundant" inspection steps, documentation requirements, and more. While this appeared efficient on paper, these were actually crucial safeguards developed from hard-learned lessons of the past.


Here's what's at stake: in industries where a single oversight can trigger catastrophic consequences, labelling such things as safety controls, "waste" is a dangerous gamble. The potential for environmental disasters, safety incidents, and regulatory penalties demands a more nuanced approach.


That's why I strongly advocate for including Lean and Compliance experts during improvement initiatives - professionals who understand both operational efficiency and managed compliance.


Remember, true operational excellence in high-risk industries isn't just about removing steps - it's about optimizing processes while preserving the controls that keep us safe.


The Solution: Lean & Compliance Expertise


Here's where I see a massive opportunity: bringing together Lean methodology and compliance expertise. It's not an either/or situation.


You can have both efficiency AND effective controls.

The key? Having the right experts at the table.


What Lean and Compliance Experts bring to the Table:


  • Deep understanding of regulatory requirements

  • Experience in optimizing control frameworks

  • Ability to spot critical vs. redundant processes

  • Knowledge of emerging risks and compliance trends

  • Expertise in designing efficient, compliant processes


Your Action Plan


Ready to get this right? Here's what you need to do:


  1. Audit Your Lean Initiatives


  • Who's on your transformation team?

  • Are risk and compliance experts involved?

  • How are you evaluating control removal decisions?


  1. Engage the Right Expertise


  • Bring in risk & compliance specialists

  • Document control rationales

  • Create risk-aware improvement processes


  1. Measure What Matters


  • Track both efficiency gains AND risk metrics

  • Monitor compliance effectiveness

  • Document the impact of process changes


Yes, Lean methodologies can transform your organization. Yes, you should be looking for ways to eliminate waste. But remember - not everything that looks like waste actually is. The key is knowing the difference.


Moving Forward


Don't let your Lean journey become a cautionary tale. Invest in the right expertise. Create processes that are both efficient AND secure. Your future self (and stakeholders) will thank you.


As you embark on your next process improvement initiative, ask yourself: "Do we really understand what these controls are protecting us from?" If you can't answer with certainty, it's time to bring in someone who does.


Remember: True operational excellence isn't just about speed - it's about sustainable, secure, and safe processes that protect your organization while delivering value to your customers.


 

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