Lean Production
Lean Manufacturing Methodology
Clients engage VIPGroup to deliver specific results in a defined, short period of time. By continually questioning established business assumptions, we are able to identify non-value added activities (waste) within your processes. Through our proven methodology, we drive out this waste thereby creating streamlined, customer-focused processes.
Together we develop a single company culture designed to pursue continuous improvement with a focus on delivering both internal and external customer needs. In working with our clients on a wide array of change efforts we have developed a phased approach that consistently delivers the sustainable results you desire.
Together we develop a single company culture designed to pursue continuous improvement with a focus on delivering both internal and external customer needs. In working with our clients on a wide array of change efforts we have developed a phased approach that consistently delivers the sustainable results you desire.
Methodologies that Fit the Organization
Selecting a transformation model or an approach for improvement is an essential step in the process. VIPGroup assesses the enterprise to identify a selection of methodologies that best suits the organization and its customer’s needs.
VIPGroup focuses on leveraging the client’s skills and knowledge that already resides within their organizations. VIPGroup consultants stimulate extraordinary thinking by the client’s management team and the employees involved in the problems to be solved.
Your employees know best what the problems are since they are living with them. VIPGroup taps the client’s existing intellectual resources through cross-functional teams that address the many issues facing the company. VIPGroup then trains problem-solving methods, tools, and project management approaches while providing guidance and coaching. The end result is a client able to solve most future problems without the need of additional consulting time.
Your employees know best what the problems are since they are living with them. VIPGroup taps the client’s existing intellectual resources through cross-functional teams that address the many issues facing the company. VIPGroup then trains problem-solving methods, tools, and project management approaches while providing guidance and coaching. The end result is a client able to solve most future problems without the need of additional consulting time.
Lean Manufacturing in a 4-Step Process
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1. In-depth operational assessment evaluates your operations, systems, processes and functionality to identify opportunities to address these factors.
2. The VIP Group incorporates disciplined project management tools and techniques, visible performance tracking systems and formal project reviews.
3. Stabilize the changes implemented and track the progress to plan. Cross-functional teams adjust approaches and plans accordingly.
4. The VIP Group develops an on-going client care program that includes pre-determined on-site follow up visits from our staff. While on site, we provide additional training, evaluation and consultations.
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Leverage and TeamworkVIPGroup focuses on leveraging the client’s skills and knowledge that already resides within their organizations. VIPGroup consultants stimulate extraordinary thinking by the client’s management team and the employees involved in the problems to be solved.
Your employees know best what the problems are since they are living with them. VIPGroup taps the client’s existing intellectual resources through cross-functional teams that address the many issues facing the company. VIPGroup then trains problem-solving methods, tools, and project management approaches while providing guidance and coaching. The end result is a client able to solve most future problems without the need of additional consulting time. |
Client FocusedVIPGroup engagements are organized to provide the least disruption to ongoing operations. VIPGroup understands that cash flow and profitability must be retained during any engagement. Therefore, the timing of the interactions with the client people is planned and organized with senior management before any work begins.
Throughout all engagements, VIPGroup provides continual updates to senior management on the progress being made. To provide growth for client employees, those working the projects own and present progress. Not only does this generate individual growth for those involved, it adds to total buy-in throughout the organization of the changes being implemented. |
Enduring Results and Benefits
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Since the people responsible for implementing and sustaining changes are involved in determining what those changes should be, the results of the VIPGroup engagements are long lasting and sustainable. Our client’s people are trained in how to identify and address problems with an improvement process initiated with VIPGroup consultants and sustained long after the engagement has been completed.
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Work in Process 30% - 90% Reduction
Process Steps 25% - 75% Reduction Mfg. Lead-Time 20% - 90% Reduction Cell Productivity 0% - 30% Increase NVA Activities 25% - 50% Reduction Space Utilization 10% - 50% Reduction Change-Over Time 5% - 75% Reduction Travel Distance 30% - 80% Reduction |
Lean Manufacturing Interdependent Elements
Manufacturing Flow: Physical Layout Changes and Process Design Standards
Product/Quality, Assessment, Process Mapping, Routing Analysis, Takt Time, Workload Balancing, Kan-ban Sizing, Cell Layout, Standard Work, One-Piece Flow
Product/Quality, Assessment, Process Mapping, Routing Analysis, Takt Time, Workload Balancing, Kan-ban Sizing, Cell Layout, Standard Work, One-Piece Flow
Organization: Identifying New Roles/Responsibilities, Training and Communication
Product-focused, multi-disciplined team(s), Lean Manager Development, Cross-Functional Skill Matrix, Training, Communication Plan, Roles & Responsibilities
Product-focused, multi-disciplined team(s), Lean Manager Development, Cross-Functional Skill Matrix, Training, Communication Plan, Roles & Responsibilities
Process Control: Monitoring, Controlling, Stabilizing and Improving Processes
5S, SPC, SMED, Poka-Yoke, TPM, Visual Control, Line Stop, Graphical Work Instructions, Continuous Improvement,
5S, SPC, SMED, Poka-Yoke, TPM, Visual Control, Line Stop, Graphical Work Instructions, Continuous Improvement,
Visible Metrics: Results-Based Performance Measures with Targeted Improvements
On-Time Delivery, Process Lead-Time, Total Cost, Quality Yield, Inventory: Turns & DOS, Space Utilization, Travel Distance, Productivity
On-Time Delivery, Process Lead-Time, Total Cost, Quality Yield, Inventory: Turns & DOS, Space Utilization, Travel Distance, Productivity
Logistics: Operating Rules and Methods for Planning and Controlling the Flow of Material
Forward Plan, Mixed-Model Production, Level Loading, Workable Work, Kan-ban Pull System, A,B,C, Parts Handling, Service Agreements, Customer and Supplier Agreements
Forward Plan, Mixed-Model Production, Level Loading, Workable Work, Kan-ban Pull System, A,B,C, Parts Handling, Service Agreements, Customer and Supplier Agreements
