Your Roadmap To Success

HOW IT WORKS:
The 16-step systematic approach to implement Lean Manufacturing practices and build a world-class operation

Developing a world-class, industry-leading operation requires proper planning, training, and implementation. It also requires diligence and the motivation to win as a team.

In today's world you want results fast and you want them to last. That's THE ESSENCE of 'Lean Manufacturing practices' – you develop a system that allows you to assess, train, and implement process improvements quickly AND permanently.

Below is a brief 16-step time overview of how we implement lean manufacturing practices:

Here's a more information on what we do:

LEAN ASSESSMENTS

Lean Manufacturing Operational Assessment – This assessment scores current practices on the shop floor and identifies where the Seven Wastes exist. This tool provides valuable insight into how your organization compares to world-class manufacturing organizations.

The assessment also identifies where to focus improvement efforts for the greatest gains. Specific Lean tools are aligned with low scoring areas to identify deficiencies. This assessment is designed for manufacturing centers, repair centers, and assembly operations.

Lean Transactional Assessment – This assessment scores current practices and services to identify where the Seven Wastes exist. This tool can be used to select the correct Lean tool to achieve the greatest and quickest gains.

Eight different categories with specific requirements are assessed to identify where Lean Practices training can help. This assessment is designed for medical center customer service, call centers, administrative functions, accounting and order processing centers, and most non-manufacturing processes.

INTRODUCTION TO LEAN PRACTICES

In these workshops, you obtain a working knowledge of Lean Practices. You come to understand how these basic concepts increase your throughput and speed your response to changing customer demands.

When you successfully use these techniques, your organization improves safety, quality, delivery, and cost. You learn how the cross-functional team approach aids to implement Lean Practices and ultimately leads to a win-win outcome for all.

5S, TOTAL PRODUCTIVE MAINTENANCE AND
VISUAL CONTROLS IMPLEMENTATION

This workshop is a mix of classroom and shop floor training that produces IMMEDIATE cost saving results. Shop floor workers and managers experience the advantages created by operators and managers WORKING TOGETHER.

Management learns how tool control impacts the bottom line and workers learn how to make their jobs easier (and more enjoyable) with tool control.

JIT AND KANBANS IMPLEMENTATION

Until now, few 'hands on' training courses included JIT and Kanban techniques. This comprehensive course allows your organization to take advantage of controlling production at the point of use on the shop floor and streamlines your movement of materials.

The operators learn how to move materials without constant supervisor intervention. Supervisors learn how to monitor production without interrupting operators.

CERTIFIED LEAN MANUFACTURING EXPERT COURSE

You earn the title and qualifications of Certified Lean Manufacturing Expert during this intensive 6 to 10 month program of learning and doing. You are trained to start and complete a entire Lean Manufacturing Improvement Project.

With this certification, you become a valuable asset to your organization as you are fully qualified and equipped to pilot your organization's Lean Journey.

IMPLEMENT VALUE STREAM MAPPING TRAINING

In this workshop, you obtain working knowledge of Value Stream Mapping. First, you learn how all the pieces of the value stream work together to produce your current state of performance. Next, you take your map to the shop floor to identify possible improvements. Finally, you develop a 'future state' map using Lean Practices principles and techniques.

Your team of participants then successfully use this training to identify safety, quality, delivery, and cost improvements. The future state map is useful for cross-functional teams to understand how their individual process impacts all the other processes.

RAPID IMPROVEMENT PROCESS

A LeanPlus 'Rapid Improvement Process' (RIP) follows an analysis of improvement opportunities and then involves your workers to implement changes that result in immediate cost savings – this includes work center layout and redesign, process improvements, and increased product flow.

During the RIP, your teams produce immediate results but also learn to facilitate future projects on their own. We train the trainers, in a sense, that will spearhead the future Rapid Improvement Processes for your organization.

Here are some the results we've seen from our RIP implementation:

An Oil Field Equipment, Maintenance Facility, Indonesia:
20% cycle time reduction, outsourced maintenance cost eliminated,
production shortages eliminated

A Tier 1 Automotive Parts Manufacturer:
- Team A plastic assembling:
80% overtime reduction, 15% increase in productivity

- Team B motors and armatures:
30% floor space reduction, 20% increase in productivity

- Team C plastic injection molding:
50% overtime reduction, 35% change-over time reduction

- Team D machine shop:
30% setup time reduction, 25% machine utilization increase

For your information, 'normal' first year return on investment is 7:1 for organizations implementing RIP programs from LeanPlus.

LEAN MERGER & ACQUISITION AUDITS

LeanPlus™ professionals are trained to identify and document production improvement opportunities or deficiencies using our proprietary methodology that's quite unlike other 'traditional' M&A audits.

While other auditors count machines, people, and materials, LeanPlus team members use their combined years experience as quality managers, production managers, and operations VPs. Sure, there are methods we use to systematically compare and score production performance – but its the experience and practical intuition of our staff that allows them to see beyond just the numbers – they see the 'true' value of an organization due to its ability to produce.

EXAMPLE: A medical device company wanted to buy a small manufacturing company that was supplying them hardware. The seller wanted $4 million. The buyer wanted to pay $3 million. A Lean Audit for the buyer revealed a potential $1 million operations cost reduction that could be achieved with less than $200,000 expense in the first year. That was an ROI of 5:1 to 7:1 that persuaded the buyer to buy the manufacturing company for $3.5 million.

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