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LEAN MANUFACTURING

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LEAN MANUFACTURING

Maximize productivity & minimize waste to create the highest value possible.   

 

Move at the speed of change & tame the volatile global marketplace.

Reduce your lead times. Slash operating costs. Maximize product quality and customer satisfaction. 

What is Lean Manufacturing?

Lean manufacturing applies specific lean practices, principles and tools used in advanced product development and manufacturing. A lean operation maximizes productivity while simultaneously minimizing waste to deliver the highest value to the customer. The goal is to fully optimize all resources, including time, materials, money and talent. 

 

Our experts can help you implement a lean manufacturing strategy quickly and at scale.

Advantages of Lean Manufacturing

  • Eliminates waste 

  • Optimizes & streamlines processes 

  • Cuts operating costs 

  • Boosts innovation

  • Reduces time to market

  • Improves product quality

Advanced Manufacturing Approaches

6 SIGMA

Identify and eliminate sources of defects and errors while stabilizing business and manufacturing processes to dramatically improve output quality.

KAIZEN

Empower employees at all levels of your company to proactively work together to achieve continuous, incremental improvements to the manufacturing process.

6S

Implement a six step methodology to create a more organized, productive and safer workspace. Optimize from end-to-end to boost work performance.

5 Core Principles of Lean Manufacturing

 

  1. Maximize Value: How much are customers willing to pay for your products? Eliminate waste to achieve the best price while also maximizing profits.

  2. Map the Value Stream: Map out the entire product lifecycle, from raw materials to supply chain to disposal. Identify areas for improvement through an in-depth analysis of product materials and resources.

  3. Achieve Flow: Tear down functional barriers and improve lead times. By minimizing delay and waste, processes become easier, faster and more predictable.

  4. Implement a Pull System: Instead of chasing estimates and forecasts, work only in response to demand. Flexibility, communication and efficiency lead to less warehousing, easier scheduling and improved customer satisfaction.

  5. Drive for Perfection: Build in a methodology that continuously improves processes on an incremental basis. This included an organization-wide culture shift as well as careful measurement of metrics such as lead-times, production cycles, throughput and cumulative flow.

 

SIX SIGMA
 

Six Sigma is a data and fact-driven approach that begins with clearly identifying what measures are integral for assessing the performance of a manufacturing operation. Advanced analysis and data collection then discover key areas to optimize process outcomes. 

 

KAIZEN
 

Kaizen creates a culture of continuous improvement where all stakeholders are involved — starting with the executive suite and continuing to each and every employee. Activities focus on improving specific areas within the company, with a special emphasis on plant floor employees. Improvement-focused thinking then becomes second nature.

 

6 Steps (6S) to Lean Management Success
 

  1. Sort: Remove unnecessary items and make all necessary items readily available.

  2. Straighten: Put, sequence, organize and arrange necessary items in a way that makes them easy to use.

  3. Shine / Scrub: Clean and clear the workplace of clutter, stains and blockages. This minimizes injuries, improves workflow and avoids product staining or contamination.

  4. Standardize / Systemize: Develop written processes to systematize the operation of the Sort, Straighten and Shine steps. 

  5. Sustain: Continuously encourage, remind and maintain good practices. Routines should reach maturity and become part of day-to-day work.

  6. Safety: Ensure that the operation of work and the work environment meet both internal and regulatory safety standards.