Lean Transformation is based on applying the Lean “Tools” to assist in the identification and steady elimination of wastes to improve flow. As wastes are eliminated quality improves while time and costs are reduced thereby creating a more nimble and agile organization. A Lean Transformation usually includes, Lean Training, Value Stream Mapping and Kaizen projects using the Lean “Tools” (6S, Visual Systems, Standardized Work, Plant Layout, Teams, Point of Use Storage, Set up Reduction, Lot Size Reduction, Quality at the Source, Total Productive Maintenance, Pull & Kanban Systems, Cellular & Flow Systems) to eliminate wastes.
- Value Stream Mapping is a diagnostic tool to visualize an organization’s internal process flow and challenges.
- Kaizen Events are used to eliminate organizational challenges identified in the Value Stream Map. The gradual elimination of non-value-added processes to improve efficiency, and add profitability to the bottom line
- Workplace Organization focuses on workflow configuration throughout the workplace to maximize productivity.
- 7-S Implementation is the first type of Kaizen that is usually performed as an outcome of the VSM. 6-S focuses on elimination of clutter in the workplace, and organization / layout of the work area.
- Visual Systems allows the many different languages being spoken within today’s organizations to understand what needs to be done. Visual systems help to eliminate confusion within the workplace.
- Visual Work Instructions (VWI’s) are tools which are used, as part of the Visual System, to assist employees in consistently producing quality work.
- Inventory Control helps minimize the cost of materials through “right-sizing” inventory.
- Kanban / Supermarket Systems are a system used to keep specific parts and subassemblies, at required levels, preferably at the point of use.
- Max/Min Replenishment Systems can be an important part of the Visual System.
- Plant / Facility Layout assures that organizations have their facility in a manner that best supports continuous workflow.
- Total Productive Maintenance (TPM) creates a program to assure that equipment is always available.
- Setup Reduction focuses on non-value-added activities that occur during a product changeover. Use Setup Reduction Programs to increase machine utilization rates and OEE.