In this episode, Tom Hughes talks with Pankaj Malik, founder of IOTAFLOW, about how finding Lean principles 20years into business revolutionized his company. From quality issues to a world-class system with 1,000 SOPs, Pankaj shares how small changes created a massive culture shift in his organization.
This shift has not only improved efficiency but has also enhanced employee well-being, with increased trust, better working conditions, and even company-funded medical care and dividends for staff.
"...it's completely mistake proof, they have that drawing to which work, one, and second they don't have to hunt for SOP or drawing anymore" - Pankaj MalikKey Topics:
How Pankaj discovered 2 Second Lean and overcame skepticism in his team
The cultural shift that helped employees see the value in SOPs
Integrating SOPs into an ERP system for real-time access on the shop floor
How Lean principles improved not just productivity, but employee well-being
The financial benefits of Lean - how IOTAFLOW reinvests cost savings into staff medical care and bonuses
"I'm doing business for 25 years now. And 21, 22 years, I was struggling so much with quality and timely delivery. And when I read about 2 Second Lean and you know it's a panacea [cure] for all these problems, I wanted to jump right into it, do everything, whatever I could. So including the SOPs and the Kanban. So we really started all together, asked my people to make SOPs. There is a struggle. There is a communication gap. If there is a quality problem, let's have a look at what is the SOP. If it is not there, let's make SOP." - Pankaj Malik
Takeaways:
SOPs are about freedom, not restriction – Employees now work without disruption, even when someone is on leave.
Integration is key – SOPs must be accessible at the point of work to be truly useful.
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