LEAN MANUFACTURING
Fed up with current factory performance? Frustrated with managers failing to deliver on objectives? Frustrated by levels of waste and rework, or just concerned about rising raw material costs and excess inventory? Or perhaps you already know you want to implement Lean, and want a way to execute so it pays for itself quickly.
Our Services
With extensive knowledge of regional and global manufacturing processes and technologies, we tailor the lean journey for your company taking into account its customer demands, environmental factors, leadership commitment, competence levels and skills within the organisation and the supply chain. Thanks to our longstanding track record of successes, our consulting services are finely honed to accurately recognize waste in overproduction, non-value-adding processes, excess inventory, quality and rework issues, wait times in work queues, poor floorspace utilization, and undue lead times associated with orders — to name but a few. We do not limit lean implementation to merely the shop floor area; but go beyond to include the leadership, human resource processes and employee motivation and involvement.
Opportunity Assessment and Value Stream Mapping
Starting with a detailed onsite review of operations, we embark on an exploratory assessment of various aspects of your organization’s supply chain, company operations, sales, marketing and management policies. We deploy our powerful set of Value Stream Mapping tools and 5S techniques to illustrate current processes, material and information-flow and identify bottlenecks to eliminate waste. Next, we identify which of the products are meeting cost and profitability targets and which are not, through SKU rationalization analysis.
After three weeks of detailed study and analysis of company operations and policies, we organize a two-to-three day Strategy and Tactic workshop with the entire top management and senior management team and walk them through the infrastructure necessary for starting and sustaining lean initiatives At the end of the session, the top management gets an understanding of all changes to be implemented in various departments, the sequence of implementation, and an assessment of the benefits. This exercise empowers the management to take an informed decision on implementation.
Lean Manufacturing Implementation
We implement a comprehensive lean manufacturing framework including Standard Operating Procedures (SOP), operating metrics, and improvement techniques to result in operational excellence. The SOPs will detail out the process standardization, more efficient workflows, and data collection to eliminate waste and economize your manufacturing sites. Benchmarks for operating metrics such as Inventory turnover, Overall Equipment Effectiveness (OEE), Cycle Time Reduction, Asset Utilization, and Changeover Time is established to build a strong foundation for continuous improvement.
We work closely with the front line managers to deploy the SOPs till the targeted benefits are realised. We organize practical workshops for operators and coaching for Front Line Management (FLM) for skill improvements on the shop floor. At the same time, we work with management to ensure the systems and behaviours to support the shop floor change exist.
Overall, we help you to build internal capabilities to drive and sustain these Operational Excellence initiatives.
Quarterly Audits and Kaizen Events
We follow up the implementation with an audit every quarter to determine if the business is properly implementing and upholding lean methodologies. This Kaizen event is a five-day team workshop, including data collection, brainstorming, training and implementation. With scoring system, question structure and scale, we assess the extent and success of implementation of lean principles in production and review operating metrics such as OEE and defect rate.
The quarterly report of improvement activities and results at all facilities will be presented to the senior leadership team, to establish priorities for coming quarter. Over the years, Consoul will help build client’s internal capabilities by creating a continuous improvement culture, by using kaizen events.