Lean Transformation Overview
Business leaders may sometimes view Lean and Continuous Improvement as specific tools to solve an isolated problem in the manufacturing plant. While this approach may be appropriate for certain situations, other situations require a leader to step back and look at the business holistically and strategically to address the root causes of their business issues. DVIRC’s Lean Transformation process, often referred to as Lean Manufacturing includes more than just tools to improve operations and processes; our experts use their passion and expertise to focus on generating and sustaining value for your organization. To be successful, Lean Transformation/Lean Manufacturing requires buy-in and commitment from the entire company – from the C-suite through the shop floor.
The DVIRC Difference
DVIRC’s approach to Lean Transformation/Lean Manufacturing 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. 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): 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.
- 5S Visual Management: 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.
- Standard Work: 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 “Kanban”: 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.
- Setup Reduction & Quick Changeover: 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.
- Total Productive Maintenance: 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.
- Leadership and Organizational Development (i.e. Effective Communication, Change Management, High-Performance Teaming, and more)
DVIRC has more than 30 years of experience working helping clients improve their people, processes, and bottom line. Our flexible engagement model enables our experts to meet clients where they are to provide right-sized solutions that will generate a positive return on investment (ROI).
Lean Manufacturing Benefits
- 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