The Definition of Lean Manufacturing
Lean manufacturing success depends on the careful application of lean manufacturing principles and activities. The definition of lean manufacturing is the performance of lean activities throughout the business process, from taking an order to collecting payment. If the organization conducts design activities, then the definition of lean manufacturing extends to the conception through design, launch, production, shipment, and service. The entire path of lean manufacturing success consists of processes-some connected, some not. Each is subject to exhaustive waste reduction-a vital lean manufacturing principle. This assessment from SAI Global with evaluate your critical business processes for waste, and identify which processes are preventing your organization from being "lean."
Lean Manufacturing Consulting
This assessment will identify breakdowns in business planning, processes, and operations that impact your customers and add unnecessary cost on your end. Such breakdowns may include non-value-added steps, unnecessary bureaucracy, poor communication, process inconsistencies, and process confusion-all of which inhibit lean manufacturing success. These costly problems can be resolved only through the application of lean manufacturing principles: if they are objectively identified, clearly defined, and subsequently quantified. These steps need to be enacted in unison with assignment of ownership for resolution.
The assessment provides a powerful tool for the senior management team, assisting them in identifying areas that need focused attention. It is also a superb tool for identifying the appropriate focus for Six Sigma Black Belts and quality improvement teams.
SAI Global's skilled professional team is able to provide your organization with the lean manufacturing expertise that will allow you to apply the principles of lean for lean manufacturing success. Our lean manufacturing consulting team is well versed in the methodology, allowing them to quickly determine the most essential problems and opportunities.
An assessment report will be prepared, highlighting those areas detrimental to the business, including customer impact and business risk. Many of these will be quantifiable in actual dollar amounts. The assessment is performed at a fixed cost to you, typically representing a fraction of the savings and improvement that you will realize after implementing the actions and achieving lean success.
After the assessment, an SAI Global project leader will facilitate a senior management planning session, where specific action items will be identified and assign to the appropriate process owners.
Assessment Deliverables
Beginning with a detailed report that discusses both the concerns of the organization and its strong points, the Lean Manufacturing Assessment Consulting program will provide you with all the tools you need to implement lean successfully. The report also designates ownership and accountability, an evaluation of business and customer impact and risk (in dollar amount when possible), and a presentation to senior management. As well, your SAI Global Lean Manufacturing consultant will facilitate a management planning session, and assign action items for the process owners.
Sample Results from an SAI Global Lean Client
A Leading Medical Instrumentation and Device Innovator and Manufacturer
Reduced the Stage Three Product Development Process time by 65%; reduced documents from 63 to 21; hand-offs from 860 to 200; distance traveled from 47 miles to 7 miles; and transport time from 17 hours to 2 hours; restructured product development team into product-focused, co-located unit with increased authority, responsibility, autonomy and risk/ reward measures aligned with company goals.
In the VAC II Disposable Pencil assembly process, we eliminated over 200 days of overtime, and reduced the people needed to build that product from 10 to 7. Through one piece flow implementation, the lead-time was reduced 8 hours to 1.5 hours; defects were reduced by 60%; WIP was reduced by 90%; space was reduced by 60%; walking distance and process distance was reduced by 50%; total savings, $120K.
In the low volume Power Pencil manufacturing process, we reduced the number of people needed to build the product from 12 to 1; productivity was improved by 67%; defects were reduced by at least 70%; lead-time was reduced from 3 days to 44 minutes; cycle time was reduced from 11.6 minutes to 3.6 minutes; process steps were reduced from 23 to 5; space was reduced by 70%; process and walking distance was reduced by 85%. This was a classic example of a one person manufacturing cell. With only a 17,000 annual volume, we were still able to save $60K+ in 5 days.
Please click to learn more about the benefits our clients have realized through Lean Enterprise.
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