Transform your company to a World-Class organization in manufacturing or service sector by implementing Lean System.
We don’t offer off-the-cuff lean stuff.
We have been there, done that, and know exactly what it takes to truly initiate, implement, and continuously carry out lean system in the long run. Our proprietary Rapid Lean Execution™ technique generates 20:1 ROI during the first 18 months after launching our lean system method.
Hoshin Kanri (Strategy Deployment)
Hoshin is a step-by-step planning, implementation, and review process which gives ‘direction’ to an organization when looking at successfully implementing future strategy. Strategic planning is a widely practiced management tool with most organizations, but they fail in deploying their planned strategies. Hoshin Kanri utilizes Deming’s “Plan-Do-Check-Act” and Peter Drucker’s “Management by Objective” to build an X-Matrix and execute objectives with a Catch-Ball practice.
5S System – Training and Implementation
5S is the foundation for creating a Lean System in the workplace. It is a systematic and standard method of organizing the workplace. Through our workshop format, your workforce will learn how a visual workplace will look and function. We guide the implementation of 5S through a series of Kaizen events that are planned to perfection and rapidly deployed with minimal interruption on operations.
Lean Leadership & Management
To implement, standardize, and sustain a successful Lean System with a practical and relatable Continuous Improvement (CI) philosophy requires a holistic view of Lean in a systems context. Lean leadership & management must consider product, people, and profit as equal contributors to an organization’s health and profitable growth. Any loss of balance on these three pillars will result in severe failure.
Lean Performance Metrics
Simple, measurable, actionable, and applicable metrics relate to product’s Time-in-System™ (TiS™) as the ultimate and true measure of lean system’s impact and organizational system’s success. Every financial, operational, supplier, customer, and cultural KPI, impacts product’s TiS™ directly or indirectly; thus causing TiS™ to be the only true lean metric.
Root Cause Analysis (RCA) & Problem Solving (PS)
As a critical part of developing the workforce, RCA & PS is designed to equip your employees with the know-how to develop a “question everything” attitude when confronted with new or chronic, problems. Tools to be trained on include: Problem Identification and Statement, Pareto Analysis, Ishikawa’s Cause Effect Diagram, SIPOC diagram, Five (5) Whys, Fault Tree Analysis, X-Y Diagram, Data Analytics (collection, analysis, trending, etc.), SPC, Run Charts, Histograms, Matrix Diagram, and FMEA.
Setup or Changeover Time Reduction
Setup time is the non-conversion time in which the product or parts are not being served. Changeover occurs when changing from one part to another, from one type of required specifications to another, or simply put, from the last output of the previous order to the first acceptable output of the next order. Four distinct activities are included in setup time: preparation, replacement, equipment location setting & measurements, and trial runs adjustment. After setup time, the ramp-up time begins which is the time after setup is completed and until the full production rate is achieved. Shigeo Shingo’s Single Minute Exchange of Die (SMED) methods systematically reduces setup time to create more capacity and flexibility.
Lean Product Development (LPD)
Most organizations do not use advanced process discipline technique and Quality Function Deployment (QFD) to effectively and rapidly develop ideas to finished products that will create a great competitive advantage in the market. We offer a structured training LPD and implement an internal effective engine that will continue generating remarkable results in completing and introducing new products to blow your competitors out of the market.