Typical Lean Implementation Process

When organisations are looking to either implement from scratch or to reinvigorate their Lean Manufacturing aspirations, there is always the question, should we go for the ‘Big Bang’ targeting the whole organisation? Or should we take a more measured approach focusing on pilot areas where the methodologies can be cascaded across the organisation as appropriate?

There is no hard and fast rule; however, we at XR find that the measured approach is more effective and sustainable. Interestingly the overall timescale is probably less than the ‘Big Bang’, because the programme gains increased momentum as the critical mass of people and process become involved. With XR’s approach ACTIVITY is the key word. All of the work performed within your organisation will be addressing your issues, resulting in real tangible and sustainable benefits. Your people will be totally involved in the improvement program, creating a sense of commitment and ownership, at all levels from senior management to shop floor worker. Lean Manufacturing can help businesses significantly improve their profitability and competitiveness.This is achieved by introducing the concepts of ‘Value Add’ and ‘Zero Acceptance’, allowing only ‘Zero Waste’‘Zero Defects’, leading to ‘Right First Time Quality’, and ensuring that all activities add value and are standardised, leading to the implementation of a robust Quality Operating System.This eliminates the risk of defective products reaching the customer and ensures that ‘Customer Demand’ is aligned to manufacturing capacity and capability. Manufacturing costs are radically reduced by eliminating the 8 Forms of Waste and increasing labour productivity. Delivery performance is improved through the use of customer focused, yet flexible, manufacturing control systems and equally, people productivity, by harnessing employee contribution as a natural part of the process.

The 8 Forms of Waste are:
● 1. Scrap & Defects
● 2. Waiting
● 3. Inventory
● 4. Motion
● 5. Transportation
● 6. Over Processing
● 7. Over Production
● 8. Under Utilisation of People

Our approach:XR are proud to offer business performance improvement processes that significantly improve quality, cost, delivery and people contribution. We use simple practical techniques to remove waste from the manufacturing process. XR’s unique ‘Do It’ approach uses LIVE issues from within the workplace, ensuring maximum benefit is achieved.We use all of the Lean tools and many more besides, but we use them collectively, not as stand-alone techniques.To expose and remove waste and non value add in the system, XR introduce a programme that management will understand and endorse, ensuring that people are able to accept the change in their current work practices and ideas, driving the principles forward with total commitment to a successful conclusion. How people accept and react to change is important, all of our programmes address this response in a structured format by addressing people’s skills, attitudes and beliefs.This ensures that these new working practices are implemented and integrated within the organisation, are self-funding, cost effective and sustainable, not just another ‘bolt – on’ technique, but a way of life and a total change in culture.

The key principles which underpin the implementation and maintenance of Lean Enterprise and the achievement of World Class Status are:

● 1. Effective Working Teams
● 2. Only Accepting Zero Waste & Zero Defect
● 3. Aligning Capacity with Customer Demands
● 4. Optimising Production Throughput

XR Training & Consultancy

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