Speed, efficiency, and customer value are critical concerns in driving results in business. Lean Strategy has helped companies throughout the world achieve huge economic benefits while improving quality, costs and cycle time. Forward-thinking companies apply Lean principles to leverage their business operating strengths and capabilities to achieve lasting change in the following areas:

• Business, Administrative and Support
• Manufacturing and Operations
• Product Development
• Supply Chain and Logistics
• Workforce Development

The Lean Strategy delivers results by focusing on analyzing and eliminating non-value added activities. It also focuses on implementing and sustaining improved processes through metrics and workforce behaviors. The Lean Transformation changes organizational culture to sustain results, creating durable and  lasting value:

• Business goals
• Strategic alignment
• Organization strengths and weaknesses
• Culture, people and practices

Many manufacturers have used Lean principals to make their manufacturing shop floor processes more effective and efficient. In most shop floor processes, labor represents 7-10% of costs. Manufacturers have found that they can reduce labor costs by an average of 40% when Lean tools and techniques are applied. These tools also shorten lead times, optimize labor and materials costs, lower inventory, improve quality and reduce scrap.

With the help of Consulting Services consultants, you can implement Lean tools relatively easily and quickly. The tools can take many forms, but each can improve throughput and productivity while decreasing cycle times and ultimately improving customer satisfaction.

Lean methods improve business results and customer satisfaction by:

• Increasing productivity and capacity utilization with existing resources
• Reducing product lead times and inventory
• Consistently delivering products on time and complete
• Eliminating root causes of defects, scrap and rework

Lean Manufacturing is a proven approach to improving manufacturing and operations – from suppliers, manufacturing and distribution, to customer receipt – with sustainable results by:

• Focusing on the flow of materials and information in manufacturing and operations
• Identifying/eliminating waste (unnecessary delays, tasks, costs, and errors)
• Implementing/monitoring an improved process for sustainability

Lean manufacturing and operations can improve productivity by as much as 20% to 45%

Lean Manufacturing Operations: Our Results Tell The Story

Client # 1: The client produces electrical  components on high speed production lines. Internal defects were a major issue:

• Annual impact of $250,000 due to defects and internal rework
• Unacceptable level of Customer complaints

Result: Using Lean Manufacturing and Operations, an improved manufacturing process was developed which eliminated the root causes of the defects:

• Implemented error-proofing on the high speed production lines
• Implemented mechanical equipment changes

Reduced Defects by 60%, saving $125,000 per year

Client # 2: The client produces chemical products on continuous and batch production lines. Sales had increased above plant capacity, causing major issues:

• Poor delivery performance (not on-time and incomplete)
• Increased internal costs, expedited freight costs

Result: Using Lean Manufacturing and Operations, an improved manufacturing process was developed which resulted in:

• Increased up-time by reducing setup & changeover time
• Clearly defined roles and expectations in the new process
• Identified and eliminated process bottlenecks

Increased Capacity by 15% to support Sales Growth