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Lean Implementation and Lean Training

Better. Faster. Cheaper. In today’s competitive world, it’s more important than ever to provide a quality product, at a low cost, faster than ever before. But how? Companies all over the world implementing a Lean Enterprise Operating System to achieve astounding results like these:

  •  30% - 100% Increased Throughput
  •  30% - 100% Increased Productivity
  •  30% - 80% Reduced Inventories
  •  50% - 80% Reduced Time-to-Customer for Order Fulfillment
  •  30% - 50% Reduced Time-to-Market for Product Innovation
  • Dramatically Improved Delivery Performance

Lean is NOT simply doing the same things, the same way, with fewer people. Lean is a systematic approach to identifying and eliminating waste by flowing the product at the pull of the customer in pursuit of perfection.

By designing processes to increase material and information flow, the velocity at which the materials move through the system to generate revenue vastly improves while using the same or fewer resources. The resulting operational improvements of cost, quality, delivery, productivity, and safety can then be leveraged to gain market share, increase profits, and increase customer AND shareholder satisfaction.

It incorporates a fundamental philosophy of continuous improvement, adopts the 3 key elements of lean — discipline, waste elimination, and standardization — and the 5 key strategies of the Lean Enterprise Operating System including:

  1. Systematic Improvement and Standardization Methodology (DMAIC);
  2. Process & Metrics for Operational & Business Results;
  3. TQM (reduce variation through six sigma);
  4. JIT (increase process speed through lean); and
  5. TPM (increase sales to capital assets).

Lean Training Enablers and Results

 Our Approach

Continual Improvement Model

We view lean as a strategic initiative that is top driven, grass-roots deployed, and mid-management fueled. Improvements are made by pursuing a parallel path of projects resulting in step function improvements along with systematic continuous improvement activities supporting the gains for incremental improvements. By developing a deployment infrastructure, expertise in application of tools and techniques, and implementing the necessary support systems, we take full advantage of a company’s philosophy of continuous improvement by building a ‘spirit’ of improvement in every individual.

Our fundamental objective is to build a core competency that is resident at your company to pursue the systematic elimination of waste to become more competitive. This means internal resources are ‘coached’ through each phase of implementation and execute projects under the guidance of an experience Lean Practitioner to ‘learn by doing’. Implementing a Lean Enterprise Operating System requires participation at every level of the organization so everyone has a role and responsibility. A Lean Enterprise Operating System requires:
  • Creation of the leadership culture and infrastructure to align the management system and organization culture necessary to implement world-class practices and performance.
  • Systematic implementation of strategies & production system integration to focus the core manufacturing techniques to achieve world-class results.
  • Integration of office floor support functions to apply improvement techniques and strategies in non-manufacturing functions within the value stream.
  • Establishing quality, cost & delivery improvements and measures that evaluate the outputs of the core business system and the performance of world-class practices.
  • Establishing customer satisfaction and profitability measures for overall customer satisfaction and business results achieved.

Customized Plan

Implementing a Lean Enterprise Operating System requires a systematic and relentless pursuit of eliminating wastes at all levels of the organization. While there is no deployment recipe, there is a roadmap. A recipe tells you exactly how to do something — the amounts, sequence and timing. There is no such recipe for lean success since every company starts with a different set of ingredients (or factors and constraints). However, there are guide posts along the way that help you determine where you are and identify potential solutions to help you get to where you want to go. The extent and degree of support needed is be a function of the current state of a company’s operations, the potential optimum state, and the current level of expertise currently residing at the company that can be leveraged to close the gap.

TMAC’s capability to assist companies in implementing the Lean Enterprise Operating System is vast and supports the 5 primary roles and responsibilities in the lean transformation journey. Whether you’re Top Management, Value Stream Management, Internal Lean Expert, Supervisor/Lead, or Operator, TMAC’s lean offerings are right for you!


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