Building a Lean Enterprise
We provide specialized support in developing and deploying Lean strategies in a single work process or throughout your entire enterprise.
- Enterprise Assessment - A customized criterion-based instrument is used for self-assessment of the entire enterprise. The results of the assessment lead to selecting the priority improvement opportunities to achieve your business goals. The assessment questionnaire is used in preparation for a senior management Planning Workshop.
- Lean Enterprise Planning Workshop - A customized three to five day work session for senior managers introduces the process management principles and techniques to define the overall value stream for the business and selects the priority targets for process improvement.
- Strategy Management - A customized enterprise-wide strategy deployment activity may be used to build alignment to priority business strategies to achieve business goals.
- Building a High Value Culture - A customized application of tools and measurements are applied to create and sustain the principles and techniques of a Lean Enterprise. This four-phase approach begins with awareness and provides the structure to pursue excellence and linkage throughout all of the value streams of a business.
- Lean Team Leader Training - Team activity is a key to successful implementation. A leadership development experience may be provided for the people who will lead the teams that will develop and implement continuous improvement.
Lean Manufacturing
Lean Manufacturing principles and techniques are applied in four phases to achieve high impact results.
- PHASE I Lean Management Workshop
- PHASE II Design & Implementation Of Model Product Line
- PHASE III Certification Of Lean Manufacturing Facilitators
- PHASE IV Creating Conceptual Design Of The Plant
This approach provides a logical yet flexible Implementation method that:
- Helps identify process areas along the Value-Stream that can be scheduled for Kaizen events.
- Implements significant improvements to a designated product line that can be used as a model for future improvements to other products.
- Develops a conceptual design (Floor Layout) of the facility, which incorporates and defines how all the product lines should look like to achieve the maximum benefits of Lean Manufacturing.
- Expedites the technology transfer of lean practices to all employees and creates a learning organization where change becomes a routine, and not a crisis.
PHASE I Lean Manufacturing Workshop
This three day workshop is designed to illustrate to your management the basic tools of Lean Manufacturing. Classroom instruction is completed in the morning and a hands on application is undertaken in the factory the remainder of the day. The four areas of learning for this workshop include:
- Visual Controls & Measures
- Standard Operations & Improvements
- Total Predictive Quality:
- Fast-Trac
PHASE II Design & Implementation of a Model Product Line
Based on an initial review, the "Value Stream " may be subdivided into several major processes. Typically, they are:
- Raw material receipt and quality check
- Machining
- Assembly of components
- Quality check, pack and ship.
Usually the design and implementation of each product-oriented cell, along this value stream, requires two to three weeks of consulting support depending on the conditions found, technical issues to be resolved, and alternatives examined.
PHASE III Certification of Lean Manufacturing Facilitators
Our approach is to continually involve support organization personnel in the Phase II workshops previously discussed. In that way, members of the support organizations are involved with the hourly employee’s implementing movements. The support organization will be the continuous improvement people designated by you.
PHASE IV Creating the Conceptual Design of the Plant
Using the model line as a paradigm of excellence, your management and Office of Continuous Improvement personnel will now be able to create a conceptual design for the complete factory operations. This phase is comprised of four significant tasks that, when completed will provide a road map for implementing future improvements. These tasks include:
- Process Evaluation
- Conceptual Design
- Organizational & Culture Analysis
- Pro-Forma Operating Statements
Lean Office - Lean Service
We provide the following consulting resources supporting your implementation of Lean Office and Lean Service.
- An introductory session to clarify the role of the management and produce a macro process description for your organization.
- An internal assessment to establish baseline metrics and target priority opportunities.
- Develop a customized process improvement methodology including process improvement event contracting, execution, and follow up.
- Selection and training of internal consultant/facilitators.
- Building your relationship with LVSI.
Introduction & Awareness
LVSI provides an initial working session to introduce the concepts of Lean Office/Service to your organization. In the session, you and your managers will use the basic tools of Lean Office to review your organization’s goals, develop a macro business process model, and establish key performance metrics. Senior management is usually the target audience for this activity.
Macro Process Assessment
LVSI will work with you to design and administer a Macro Process Assessment. It is an overall study of your business unit that examines the important aspects of customer value, the organization’s strengths and weaknesses, and opportunities for improvement.
It begins with the macro process definition and performance metrics developed by the management team. A criterion based evaluation tool is then designed to assure that the characteristics that influence your priority business concerns are evaluated.
Developing Methodology
LVSI will help you select and customize the elements of the Process Value Management (PVM) methodology consistent with current best practices in the discipline.
Building Your Capability
LVSI will help you develop your internal capability to perpetuate the application of Continuous Process Improvement throughout your organization. LVSI LLC will train and coach your internal Process Improvement Facilitators in the use of the methodology.
Process Improvement Implementation
Experienced LVSI practitioners will partner with your staff to lead one or more pilot PVM events. The events will address one of the vital opportunities that will be identified during the macro process assessment. Process Improvement Teams will "improve" key business processes beginning with understanding the current process and concluding with implementation of changes.
LVSI will provide the guidance, coaching, and feedback to give your staff the "live" experience as process consultants. Each development session with your staff will include specific observations, complete analysis of individual and team performance, and personal feedback. We will support your staff development until they are capable of working on their own.
Follow-up
Experienced LVSI practitioners will work with the team leadership to assure the implementation of the team’s action plan. Although this is considered the "final" phase in any process improvement effort, it is actually the beginning phases.
Kaizen Events
Lean Manufacturing
We provide our clients with the following Lean Manufacturing (Kaizen) services to help them remain competitive in today's markets:
Kaizen - A two week, seven- or five-day workshop conducted on the floor with a mix of employees. This workshop teaches the fundamentals of the Toyota Production System Methodology and implements improvements at the same time!
Standard Work - The most powerful tool within the Toyota Production System Methodology. Learn how to flow work, operators and machines to TAKT TIME!
Cellular Manufacturing - Understand the concepts and implement the change in your organization from batch processing to cell processing.
Set-up Reduction - Take machine set-up times from hours to minutes to seconds! Learn how to combine the resources of the floor, tool room and support groups in identifying waste in set-ups.
Visual Factory - Increase productivity by making your factory easy to navigate and improve the flow of vital communication to the floor!
Total Preventive Maintenance (TPM) - A one-week workshop that is comprised of operators, maintenance personnel and supervisors to implement a total productive manufacturing system for increased machine capacity and up-time.
We can provide you with greater detail on any or all of these concepts. Please contact us for additional information as to how these Lean Manufacturing Tools can be applied within your organization!
Value Stream Improvement Events
Lean Office or Lean Service
Lean Enterprise or Lean Office extends the Lean Manufacturing concepts beyond the production floor into the administrative, support, and service functions. It helps you understand what you must do to assure that your customers are satisfied. Not just by the actions of a single a single organization or function, but cross functionally! We use a proven methodology called Process Value Management (PVM) to implement Lean Enterprise in business processes.
The time commitment for Lean Office events can be two weeks, seven-days or five-days. The workshops are conducted in the work area with a mix of employees. This workshop teaches the fundamentals of Lean Thinking and implements business process improvements at the same time.
Lean Office events are tailored to the type of business process and are begun with a consultation between the business managers and our experienced consultants. The consultation develops the goals, objectives, and defines the deliverables and team membership for the event. The team event completes the process analysis and develops process improvements.
