Areas of Expertise
The LEAN transformation is not as daunting as you might think. We encourage you to just get started. You'll be amazed at how small changes and incremental improvements can really make a difference. If you're newer to LEAN, we provide a powerful kick-start to your LEAN journey. Our hands-on approach will first demonstrate LEAN's power and then propel you towards greater success. If you're a seasoned LEAN practitioner or organization, we'll partner with you to improve your competitive edge and to develop even more core competencies.
Here is the typical approach that we take, which scales up or down to meet client needs and budget:
LEAN Evaluation, Assessment and Scorecarding
Our onsite LEAN evaluation, assessment and scorecarding process takes a comprehensive view of your targeted business operation(s). Although every company is different, the process typically takes two or three days to complete. The initial business tour will determine which components are necessary for your particular situation. Here are just some of the assessment categories we like to explore:
- Maintenance and Machine Effectiveness
- Layout and Floor Space Use (e.g., profit per sq/ft)
- Production Planning and Inventory Management
- Capacity and Volume Analysis (i.e., Constraints and Growth Capability)
- Labor Models and Crewing Process
- Labor Utilization
- Cost of Current State
- 15-Point LEAN Assessment
Solid planning leads to better strategy formulation, which is your road map to success. Kaizen Assembly’s suite of strategy models are very effective in creating a foundation for continuous improvement. This includes the project management tools necessary to facilitate ongoing kaizen events (i.e., LEAN implementation). We help identify Key Performance Indicators, a quarter-by-quarter implementation schedule, steering committees, project charters, team selection criteria, and much more. Strategy sessions typically range from two to three days.
LEAN Training and Coaching
Both LEAN training and coaching are key components of your LEAN success. We will identify the specific LEAN concepts necessary to balance your desired results with the level of change your culture can readily absorb. We prefer to train and coach leadership, management, supervisors, line workers, and operations staff before, during and after the LEAN transformation. Onsite training typically ranges from one to three days. Topics may include:
- Value Stream Mapping
- Data Collection
- Cell Manufacturing and LEAN Assembly
- Standard Work
- Total Productive Maintenance (TPM)
- Setup Reduction and Quick Changeover
- LEAN Office and Service Providers
LEAN Implementation (Kaizen Events)
Kaizen Assembly has facilitated over 400 kaizen events in multiple industries. We will lead you through each event, to properly execute the LEAN strategy and to meet your project goals. We provide a level of expertise and leadership that has earned us international awards and credentials. Kaizen events range from three to five days in length and involve a cross-functional team of your employees.
Throughout your LEAN journey, we provide ongoing status checks, participate in meetings and provide any necessary kaizen event support. We even offer onsite manufacturing engineering support, through our third party engineering partners.