Today, there are many consulting companies that help companies to incorporate the Lean process into their manufacturing processes. The consultants lead, instruct and launch the companies so that they become lean in their manufacturing activities, product development and relationship with suppliers.
The manufacturing consultant work with you in the development of your Lean strategy, prioritize the necessary changes and implement them to the point of continuous self-sustained improvement.
The first phase in Lean methodology begins with a clear idea of how your company creates its products. The consultants evaluate current practices to identify the specific gaps between existing operations and those that are really scarce. This review includes programming, inventory management, customer service, communications and quality, interviewing key personnel, reviewing procedures and observing all the processes that take place in your organization.
The second phase detects avoidable costs by identifying wasted materials and work tasks through the Global Equipment Efficiency (OEE) studies, reducing configuration times and implementing 5S methods.
The third phase involves the reduction of variability through improved flow and quality, focusing on efficient operations and minimizing error. This process includes the optimization of the work rhythm, the manufacture at the point of use, the total productive maintenance practices, the push yoke and the use of various lean statistics tools.
In the fourth phase, an extraction system based on demand is calculated and executed to reduce the general inventory, order delivery time and work in progress. The techniques “Just In Time” and “Kanban” are also introduced to improve delivery time and reduce inventories.
The final phase focuses on Process Control: the foundation of a continuous process of continuous improvement. The consultants also provide full on-site training for all stakeholders, including the use of simulations and the creation of infrastructure that will help the organization achieve operational excellence.
Ultimately, consultants will instill a culture of continuous improvement in their organization and create key performance indicators that management can use to adjust their overall performance.