Lean Consulting

Improve operational efficiencies, increase profits, and create a more empowered and engaged culture.

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To be successful, Lean Manufacturing requires buy-in and commitment from the entire company – from the C-suite through the shop floor. DVIRC’s approach to Lean Consulting includes coaching employees, teaching them how to implement processes, and helping them develop skills that will ensure your company’s long-term stability, overall growth, and competitiveness.

Our experts work with you to assess your operations and identify the desired organizational direction. They evaluate all of the Continuous Improvement services available, as well as the desired behaviors (sometimes referred to as soft skills) for sustainability.

Average Lean Consulting Impact

infoAll companies that engage in projects with DVIRC are surveyed by NIST through the Fors Marsh Group, an independent research firm, to validate both the quantitative and qualitative impacts. These metrics are an average per engagement since 2018.
Increase in Sales
Increase in Sales
Retained Sales
Retained Sales
Cost Reduction
Cost Reduction
Investments Made Back Into the Business
Investments Back Into Business
New and Retained Jobs
New & Retained Jobs

Lean Consulting Elements

We will work with your organization to create goals and objectives aligned with the organization’s strategic plan, a clear line of sight to areas of improvement, and a customized deployment plan. These services include but are not limited to:

Value Stream Mapping (VSM)
5S Visual Management
Standard Work
Pull “Kanban”
Setup Reduction & Quick Changeover
Total Productive Maintenance
Leadership and Organizational Development

By using the VSM process, DVIRC helps clients detail each significant process step and evaluate how it’s adding value—or not adding value—to the customer, enabling clients to compete more effectively in the market. Lean practitioners can effectively use VSM to produce the most value for the customer in the most efficient way possible. Our VSM process allows you to see not only the waste, but also the source of the waste.

The 5S system is a series of activities designed to improve workplace organization and standardization. The system stops the causes of errors and defects that later become larger workplace problems.

Every process can be made more efficient, but instead of investing large amounts of time and money for improvements, Kaizen Continuous Improvements are small incremental improvements that can be made by everyone in your organization by improving standardized activities and processes. Standard Work documents the current best practice for performing a task or process and ensures that everyone is applying it.

Pull systems allow the person doing the work to pull in tasks as they are ready. This prevents people from feeling overloaded and forces teams to prioritize. This means that project managers and team members can focus on the right tasks at the right times while reducing wasted time or effort. Kanban, a scheduling system for lean manufacturing and just-in-time manufacturing, is the most popular way to establish and maintain a pull system.

Through this process, each element of the setup/changeover is analyzed to see if it can be eliminated, moved, simplified, or streamlined. Changeover times can be dramatically reduced – in many cases to less than 10 minutes.

TPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. The TPM process is ideal for any business looking to improve equipment uptime and productivity, optimize capital investments, improve service delivery time, and reduce inventory.

Effective Communication, Change Management, High-Performance Teaming, and more.

Lean Consulting Impact

Cost savings of $100,000 or more in the first year

15% or more increase in overall capacity and productivity

Improved employee retention

30% faster employee “onboarding” times

20% average improvement in on-time delivery and lead time to customers

Lean Training Overview

Lean/Continuous Improvement Content Expert, Nico de Sousa Serro, explains DVIRC’s unique approach to Lean Training.

Upskill your workforce and develop a culture of Continuous Improvement. Join us for one of our upcoming open-enrollment Lean courses or contact us today about holding an on-demand Lean program at the convenience of your facility.

Client Testimonials

“I like that we can customize the program to fit our needs and as we evolve as an organization, we want to be able to pivot and change with new ideas and opportunities to get better. The key aspect for us is being able to customize training, take advantage of the latest techniques and benchmark from the best in business.”

Peter Rapp

West Whiteland Site Manager, Johnson Matthey

“DVIRC advisors are down to earth and very responsive. They have experience in the business world and with other manufacturers and bring a lot of value to the table.”

Alan Thompson

President, Tech Tag & Label

“DVIRC was very attentive to our strategic interests and adapted their Lean efforts to who we are and what we wanted to accomplish. I wanted Turkey Hill to become self-sustaining as quickly as possible. DVIRC has been wonderful at helping us develop our own programs.”

John Cox

Executive Vice President, Turkey Hill

“DVIRC has done more than 20 Lean project sessions with us over five years. Their expertise is highly valued. Our DVIRC consultant had great expertise in both manufacturing operations and Lean techniques. He could identify a problem in just one or two visits.”

Ernie DeLany

Owner/CEO, Probes Unlimited

Success Stories

Liberty Coca-Cola

Liberty Coca-Cola

Beverage Icon Liberty Coca-Cola Retains DVIRC Six Sigma Experts Resulting in $1.4MM in Initial Cost Savings

Johnson Matthey

Johnson Matthey

DVIRC Winning Teams™ Generates 600% Return on Investment through Lean Process Improvements Combined with Employee Training for Johnson Matthey

PAC Strapping Products

PAC Strapping Products

PAC Strapping Increases Sales and Improves Efficiency Through DVIRC’s Six Sigma Training

Take the Lean & Six Sigma Self-Assessment

DVIRC Lean Assessment Score

DVIRC has created a Lean & Six Sigma Self-Assessment to help you understand the opportunities you have to leverage process improvement and talent development within your organization.

Our goal is to help you identify areas in the organization where you can eliminate waste, reduce costs, improve the performance of your staff, and increase your bottom line moving forward.

Take the Assessment

Meet the Lean Experts

Alan Shell - Director of Lean/Continuous Improvement Services, Master Black Belt

Alan Shell

Director of Lean/Continuous Improvement Services, Master Black Belt

Alan Shell is the Director of Lean/Continuous Improvement Services at DVIRC. He is responsible for facilitating organizations in their Continuous Improvement journey utilizing his Master Black Belt skills in Six Sigma and Lean Manufacturing. This involves on-site training and collaboration, as well as leading public training and education courses and certifications held at DVIRC.

Nico de Sousa Serro - Lean/Continuous Improvement Content Expert

Nico de Sousa Serro

Lean/Continuous Improvement Content Expert

Nico de Sousa Serro is the Lean/Continuous Improvement content expert at DVIRC. He is responsible for facilitating organizational continuous improvement efforts, implementation of Lean methodologies, and creating Lean/CI content. This involves developing on-site collaborative solutions and training, as well as conducting training and education courses held at DVIRC. Nico has extensive experience in process improvement and Lean philosophy implementation, having driven many initiatives on manufacturing plant floor settings.

Vivienne Baxter - Senior Manager, Training & Organization Development

Vivienne Baxter

Senior Manager, Training & Organization Development

Viv Baxter is the Sr. Training Specialist at DVIRC. She is responsible for consulting and providing training, professional development, and employee engagement solutions. This involves needs assessments, developing on-site collaborative solutions and training, as well as conducting training and education courses held at DVIRC.

Jeff Kopenitz - Advanced Manufacturing Lean Master, Shingijutsu Japan

Jeff Kopenitz

Advanced Manufacturing Lean Master, Shingijutsu Japan

Jeff Kopenitz has more than 38 years of experience in the manufacturing and service industries and has expertise in Lean Six Sigma training and deployment. Jeff integrates the social side / human side with the technical techniques of Change Strategies. His coaching work with frontline and senior-level leaders provides alignment across the organizations. Jeff believes that “A workforce without the power to think is like having a vehicle without an engine, it’s going nowhere”. He strives to make sustainable continuous improvement part of a company’s culture by incorporating organizational development, systems thinking, and change management techniques into his education training and consulting practice.

Begin your lean transformation today.

Begin your lean transformation today.

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