What To Expect With Lean Manufacturing Consulting

 By choosing a good lean manufacturing consulting company, you can expect well defined and measurable changes in your operations. It is not enough to just improve, there must be a decisive and tangible improvement.

Since the definition of lean manufacturing is continuous improvement, you should expect to see exactly that, otherwise, your efforts are in vain. Your consultant will be able, in a very short amount of time, to give you a fairly clear idea of what to expect from your investment and efforts.

The lean manufacturing process

Some companies try to imitate the Toyota auto company in their process. This is understandable, since Toyota developed the program and has been the most efficient car company in history. This approach is flawed, however, because each business is unique and has it's own needs, limitations and culture.

The main concept that is so difficult for managers to grasp is that the lean manufacturing process is a culture, it is a way of thinking and acting that effects everything it comes in contact with. It is not a bunch of rules, procedures, or programs that are applied to a business.

Kaizen training

Kaizen is an approach to improving processes in small increments by using teams. This is quite different than the usual top-down approach to making improvements. Many businesses claim to welcome employee involvement, but in reality, the fact that there is so little shows that this is not really the case.

When the people who are actually working on a process are empowered to cooperate with one another, as well as with management, truly remarkable improvements can take place. Since they are the ones doing the hands on work, day in and day out, they know where the waste occurs. By working together solutions can be found and implemented quickly, without a lot of analysis and discussion.

All too often, good ideas go nowhere because, once they are submitted to the superiors, the idea just languishes in a pile of paperwork. Small changes occurring frequently add up to be major changes that last. The Kaizen blitz is a fast and decisive action to make improvements in a process or work area. This is an effective tool that empowers and includes the worker with the lasting results.

Your lean manufacturing consulting partner will provide your workers Kaizen training. Part of this methodology is that:

1. No money will be spent

2. No people will be added

3. No space will be added

In reality, money will be saved, people will become better, happier workers, and work space will be gained as a result.

What are some typical results of Kaizen?

1. 50% reduction is manufacturing space

2. 45% improvement in throughput time (lead-time)

3. 65% reduction in work-in-process

Conclusion

A good lean manufacturing consulting firm will embrace manufacturing excellence by using the tools and philosophy of the Toyota Production System (TPS), which is also known as lean manufacturing. By using continuous improvement, or Kaizen, waste is reduced or eliminated in any business venture.

The tangible results of your program should be seen in a few days, not weeks or months. Improvements will be readily experienced by everyone involved.

Your consultant will show you how this is a far-reaching philosophy, not just a bunch of productivity tools to be applied. As Kaizen becomes part of your culture, continuous improvement will happen everywhere.

As you progress down this path, you will embrace the 5S Implementation Methodology, Value Stream Mapping, and Six Sigma. These are all very critical parts of any lean manufacturing process.

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