Our Consulting Services

Lean Manufacturing

What We Can Do?

Lean manufacturing revolves around five key words:
(1) What's 'value'?
(2) Value stream
(3) Flow
(4) Pull, and
(5) Perfection.

It revolves around the word 'zero' with a strategy to 'eliminate'. For example, zero Inventory, zero Defects, zero setup, zero breakdown, zero Paperwork, zero search times, zero overheads, zero discrepancies, zero Misalignment (of people with strategy), and zero miscommunication.

Lean has many improvement strategies such as 5S, standardized work (time standards, takt time and SOPs), QFD, visual controls, quality at source, point-of-use stores, JIT purchase, quick setup/SMED, Poka-yoke, Kanban pull system, cellular layout, U-lines, one-piece flow, TPM, multi-skill charts, quality circles, suggestion schemes, small group activities, SITG projects, Kaizen, A3 management process, six-sigma business process reengineering, and theory of constraints.    

The following are general steps of our methodology:

1. Conduct 5S audit
2. Train employees in 5S and implement 5S principles
3. Conduct lean audit (how material, machines and people spend time)
4. Present the findings and scope for improvement
5. Develop an implementation plan (on flow, pull and perfection)
6. Train the key employees in lean principles
7. Analyze current layout and flow
8. Rationalize manufacturing, create U-lines and supermarket system of pull
9. Strive for "one-piece-flow"
10. Define revised job descriptions and performance metrics
11. Implement appropriate improvement strategies (as given above) to make the company world class
12. Continually improve using A3 management process.