The effectiveness of using learning factories to impart lean principles to develop business improvement skills in mining employees

Abstract

The purpose of this research was to investigate the effectiveness of Learning factories in imparting Lean principles in order to build Business Improvement skills of mining workforces. This study was conducted at a training centre established by a mining company in South Africa. Two groups of participants with employees at two different employment levels were trained at the centre in foundation Lean principles. The Kirkpatrick model for evaluating effectiveness of training was chosen as a tool that can be used to evaluate the effectiveness of this Lean training. This was achieved using before-and-after questionnaires, visual observations and process data from improvement projects identified by the participants. The results showed that the Learning Factory is effective in imparting the Lean skills across hierarchy levels in a mining operation within a short space of time. Furthermore, all employees arrived at the same overall Lean understanding post training regardless of their starting point. Where project implementation was done, it was found that the participants were able to apply most of the Lean principles in the workplace. A major shortcoming observed was that the main focus was on technical aspects of Lean with little regard for other aspects that contribute to sustainable Business Improvement such as change of culture. Lastly it was found that while the Learning Factory can assist in building Lean capability in an implementation, the other success factors such as management buy-in and workforce support can enhance this effort. One recommendation is to do a study to determine the interrelated nature of the factors that drive a successful Lean implementation and the role that a change management program like ADKAR can play to maximise success.