Frequently Asked Questions about Lean/Process Improvement
What types of activities does Business Process Improvement utilize?
What types of activities does Business Process Improvement utilize?
Business Process Improvement typically utilizes the following activities:
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Lean Manufacturing workshops (Cycle Time Reduction)
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Train team on principles of Lean Manufacturing, set goals and objectives for workshop, define the "current-state", develop measurements
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Mapping the current and the ideal process (Value stream mapping)
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Problem solve and determine root causes, develop, prioritize, and test solutions
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Verify improvements, define new standards and measurements
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Outputs are elimination of waste with faster, easier, and more efficient processes
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Quality improvement
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Variation reduction (Define, Measure, Analyze, Implement, and Control)
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Work Standardization
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Do you offer Automation/Software implementation services?
Our process improvement methodologies specialize in driving improvements using no cost/ low cost solutions. However, teams we work with do consider technology solutions after utilizing no-cost/low-cost solutions to cut waste. Typically for these technology solutions to make business sense, we recommend that the return on investment is realized within one year.
We do consult with companies to help them determine if and when automating their operations makes business sense and in some cases help them determine what automation or software solution fits their needs. For companies in the high tech avionics and medical device manufacturing industries, we participate in ERP/MRP software implementation services in conjunction with Software21.
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Can I improve a process simply by automating it?
Typically processes that haven't been streamlined have redundant steps and quality issues. If an inefficient and mistake prone process is automated, the result will be that the mistakes happen faster and the system will be out of control. We recommend streamlining a process first, and then if automation is desired at that point, to implement the software solution. It is easier and cheaper to automate a process with higher quality and fewer steps. You'll get much better final result by streamlining and then automating the process.
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I've heard about Lean, Six Sigma or Sigma Variation Reduction, DAMIC, Theory of Constraints. How do I know what's the best methodology for improving my business?
We are proficient with all these improvement tools and methodologies and work with your team to tailor a process improvement program that is a good fit for your industry and business objectives. We know how to utilize the tools of process improvement, Lean (cycle time reduction) and variance reduction (Six Sigma) to drive improvements.
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What is Lean and what are the Tools of Lean?
Lean is organizing the processes of an organization to delight the customer by:
The Tools of Lean include the following:
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Value stream mapping
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Activity based mapping
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Product mapping
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Waste identification and elimination
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Standardization
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Work in process
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5 S's - Sifting, Sweeping, Sorting, Sanitizing, Sustaining
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Error proofing
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Total Productive Maintenance
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Sigma Variation Reduction
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Lean Management
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What are the 7 Types of Waste that Lean strives to eliminate?
The 7 Types of Waste are:
What's the origin of Lean?
Lean was started in the 1950s by the Japanese who created the Toyota Production System to allow them to be competitive against the then dominate American automakers.
We want to do Lean in-house. Can you help us implement Lean and provide "train the trainer" services and so we can continue to improve on our own?
Absolutely - We can work with you to develop a Lean program that is a good fit for your industry and company. We provide the training and development to key individuals within your company and go through a series of Rapid Improvement Workshops with your trainers. After a set number of workshops are successfully observed, co-facilitated and facilitated by the in-house trainers, we step back and you become self sufficient in your lean activities. We do like to check in with our clients quarterly or bi-annually to make sure improvements are maintained and to provide any additional assistance needed.
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What is the difference between Lean and Six Sigma?
Lean and Six Sigma are both tools utilized to by companies that are looking to improve their services and products for the customer. The short answer is Lean speeds up the process and Six Sigma is a measurement of variation (so Sigma Variation Reduction's goal is to minimize variation). We work with our clients to tailor a process improvement program that utilizes the necessary tools to get the results they're looking for.
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