Lean Manufacturing

 

 

Delivering Enterprise Value Through: Lean Manufacturing, Theory Of Constraints and Supply Chain Optimization

Experience Driven Consulting

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The approach to Lean Manufacturing should be holistic yet has a focused practicality to deliver results. Each step is driven by the organization's key business needs and objectives.  Delivering results is the tangible evidence that the organization is buying into and embracing Lean.  Therefore, the organization is building lasting value not short term payback that fads as soon as the consultants leave.

But,  are you wondering why embark on a Lean initiative? Check out the inventory turn differences between the automotive industry and the rest of US manufacturing in this slide from the Lean Enterprise Institute. Inventory turns are certainly only one benefit of a Lean initiative, since we seek to ELIMINATE all waste there are many cost, overhead, quality and material savings as well.

The practices encompassed in a typical Lean project include many aspects of the organization and its business processes. We show these practices as fitting into improving the three cornerstones of Lean: culture, standards and flow:

 
Executive leadership Visual control Cellular flow
Employee involvement Process standards Kanban
Customer satisfaction Poka yoke Flexibility
Quality 5S Quick changeover
Continuous improvement Maintenance Supplier integration

 

There is a phased approach to working with Lean starting with education and initial alignment around Lean principles.  While there are many paths to Lean success, a pilot and focused initial scope is helpful is showing how Lean works and demonstrating change.

Click on the phase below to download a PDF Roadmap for each Lean phase that shows the flow of work steps and deliverables for a typical Lean transformation.  These roadmaps help your team 'see' the path forward and envision the steps to achieve success:
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Diagnostic & Vision - Phase 1

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Design & Build - Phase 2

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Implement & Monitor - Phase 3

Ready to see how your operation compares to the Lean practices?  Download a PDF document to survey these Lean practices across your operation.  There is one page for each of the key practices above with 6-8 key questions to delve into the extent each practice is implemented across the organization.  Assess your operation and find valuable gaps and opportunities:
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Lean Practices Survey

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Sample practices summary

bulletTheory of Constraints
bulletSupply Chain

 

 

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© Kirk D. Zylstra, 2004-2005 all rights reserved

Last modified: November 25, 2005