Lean Made Simple STEP6 - Introduce Improvement Time with Declan McKeever
Join us for an insightful conversation with Declan McKeever as he shares his experience implementing *Improvement Time* at Seating Matters and SDC Trailers. Declan discusses the transformation from a chaotic factory to a structured, people-driven lean culture. Learn how small daily improvements can lead to massive long-term gains, and discover practical strategies to apply *2 Second Lean* in businesses of all sizes.
👉 *Key topics include:*
✔️ How to introduce and sustain Improvement Time
✔️ The biggest mistakes companies make with Lean
✔️ The balance between production and continuous improvement
✔️ Why mindset is the biggest factor in successful implementation
✔️ How to engage employees and overcome resistance
If you're looking to *eliminate waste, improve efficiency, and build a strong Lean culture,* this is a must-watch!
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0:00 - Introduction & Declan’s Lean Journey
1:51 - Before Improvement Time at Seating Matters
5:40 - Challenges with Initial Changes
6:56 - Why Wasn’t Everyone Involved at the Start?
8:04 - Declan’s Move to SDC Trailers
9:26 - How Improvement Time Works at SDC Trailers
10:19 - Starting Improvement Time in a Small Company
11:21 - Key Learnings from the Lean Journey
13:03 - Balancing Dedicated Improvers vs. Everyone Improving
14:56 - Does Improvement Quality Matter?
16:32 - Best Way to Direct People’s Focus in Improvement Time
18:32 - Is 3S Different from Improvement Time?
20:20 - Overcoming Resistance to Improvement Time
22:58 - The Mindset Shift from Japan
24:45 - Tipping Point: Seeing Improvement Time Work
28:52 - Balancing Improvement Time with Production Time
32:21 - Transitioning from Seating Matters to SDC Trailers
35:29 - Biggest Mistakes People Make with Improvement Time
39:44 - Did WhatsApp Help with Lean Communication?
40:25 - The Mindset Shift That Changed Everything
*Key Lean Principles Declan Explains:*
#### *1. Start Small & Build Momentum*
Begin with a small team of passionate individuals.
Educate them deeply before expanding lean efforts company-wide.
#### *2. Improvement Time Must Be Structured & Controlled*
Improvement time should focus on problems affecting the customer.
Without structure, improvements can conflict or be undone.
Use visual tracking (boards, lists, WhatsApp) to manage improvements.
#### *3. Balance Improvement & Production*
Adjust production *takt-time* to free people for improvements.
Have dedicated improvement staff but involve all employees.
#### *4. Start Fast, Iterate, & Refine*
First idea = worst idea, but also the most important.
Use rough prototypes (cardboard, tape) before refining.
Act **immediately**—don’t delay improvements.
#### *5. The Power of Visual Management*
Make improvements obvious with labels, colour-coding, and organisation.
Ensure every tool, part, and process is easy to understand at a glance.
#### *6. Engage Employees at All Levels*
Leadership must be visible on the *Gemba* (shop floor).
Ask good questions instead of giving solutions.
Teach people how to see waste by **working alongside them**.
#### *7. Learn from the Best & Adapt to Your Business*
Lean principles must be tailored to each company.
Visit lean companies, read books, and **continuously learn**.
#### *8. Culture First, Tools Second*
Lean is about **people and culture**, not just tools and systems.
Breaking down hierarchy (open offices, uniforms) improves teamwork.
#### *9. Improvement Time Creates More Time*
At first, stopping for improvement feels like a slowdown.
Over time, efficiencies free up more time for better improvements.
#### *10. Mindset is Everything*
Declan’s *biggest change* came from a mindset shift in Japan.
Seeing Lean in action made him realize the potential of improvement time.
*“The only thing that changed was my mindset.”*