What is lean manufacturing?
The concept of Lean Manufacturing is a trend in today’s industry. The goal of the transformation is to obtain additional profits by reducing losses at all stages of the product cycle, from customer order to delivery to the end consumer. Optimization should free up wasted resources. It is not a question of physical thrift, but of reducing labor, time, and material losses.
According to statistics, as a result of the reconfiguration of administrative and production processes, the efficiency of the business as a whole can grow by 20% or more: quality, productivity and cost performance improve.
The principles and approaches of Lean Production are inherited from Toyota’s production system. Back in 1912 the concern showed the whole world how it was possible to outstrip competitors in a matter of years and become an example in its industry without major capital investments, based on the optimization of each of the links of material and information flows. Toyota has cut its costs and put those resources toward modernization. The introduction of Lean Production, as well as the program module of staff training, is usually developed individually, but the general steps of the introduction of Lean Production and Kaizen, as well as the fundamental elements of the Lean Production training program for over 100 years remain the same.
The process of transformation of the enterprise
The process of working with a particular company begins with a study of its current state in general, as well as all the major processes in particular. Based on this information, a model is built – the stages of transformation of each of the links. The task of all steps is to eliminate any losses, to find an opportunity to redistribute resources. As a result of the work should eliminate unnecessary costs:
- overproduction, storage of over-issued stocks;
- Useless displacement, idle warehouses, transfers;
- insignificant processing steps, marriage;
- losses due to late deliveries of raw materials or products to customers.
The process of transition to such a principle of activity involves: the development of principles for further action by each of the groups involved; kaizen training of all staff, periodic monitoring, showing how well the program is implemented Lean production and adherence to the specified model.
Advantages of Lean Production implementation program
The lean production implementation and training program from Bpi Group (Kiev) is a comprehensive service. The result of the consultants’ work will be a clear and achievable plan, adhering to which the company will increase productivity and profits by reducing all types of losses and not only.
All participants in the process are involved in ensuring the implementation of the implementation program, and each has their own stages of growth. Executives receive new instructions: middle management – understanding of local goals, conditions and knowledge of methods to achieve them, the management team – a global strategic vision of the production system. And most importantly, everyone will be involved in building their own Lean Production system and creating the conditions for its continuous improvement. Competently launched the process of transformation of the company once, will be the basis for further effective production for decades to come.
About the program
The program is comprehensive and includes all of our services: production system audit , strategy development и management model tuning . The program is a system of actions that triggers and supports the necessary changes to transform a business into a great business and an organization into a great employer. It is based on the guiding principles of the Shingo Modelfor Operational Excellence. The guiding principles reflect values and form a code of conduct – the culture of the organization. Thus, by managing behavior (culture), you predetermine the result, that is, such operational indicators as quality, productivity and costs. Also, the program uses the methodology of CDI Way (Mini-Business Units) for policy deployment. The program’s action system is harmonious, which means that each tool in the action system plays an important role, but is not capable of delivering the results that the action system as a whole can. The system of actions of the program is harmonious, which implies that each tool in the system of actions plays an important role, but by itself is not capable of providing the result that the system of actions as a whole is capable of.
Phases of transformation
"Born to crawl" is not a sentence if you aspire to fly!
PHASE I
Changing perceptions of oneself
Restoring the health of the organization
Stage 1. Audit, planning, and management involvement.
Stage 2. Providing information support for change.
Step 3. Staff development and the introduction of daily management standards.
PHASE II
New skills. New behavior
Process and flow optimization
Step 4. Standardization of processes and working environment.
Step 5. Implementation of focal improvements in the flow.
Step 6. Deploying policies and defining KPIs based on local goals.
PHASE III
Maturity. Kaizen Culture
Operational Excellence. Kaizen
Step 7. The elevation of new practices to the status of cultural traditions of the organization.
Download our transformation program!
The downloadable PDF booklet contains a detailed description of each stage of the transformation: what problems are solved, what actions are taken, and what the expected result is. Fill out the form and download the booklet file.