Lean Operational Excellence

Why is it important?

Due to the unstable business environment over the last 2 years, companies across all industries are looking for the opportunity quickly and flexibly adapt and improve their operations within the new reality. Our clients are facing challenges with the supply chain, higher prices for raw materials, which increased operational costs and influenced the efficiency of capital projects and launching new products. In solving these issues, organization’s necessity to take part in building sustainability, and implementing cultural and digital transformations.​

Our experience

Lean Coaching has a wide range of experience in operational excellence projects and big transformation (Lean, Digital, ESG) programs towards the common business issues which are required a combination of deep industry knowledge with the practical experience in the operations improvement sphere.​

Optimization in Operations​

Operations are your business’s day-to-day organizational activities that create unique value and achieve core objectives.

What is it?

Operations play distinctive roles that contribute towards the overall success of the organization. Our service “Optimization of operations” targets maximization of efficiency, focuses on the increase of productivity and profits while reducing costs. All of that while sustaining high quality of products and services.

Why is it important?

Your company’s operations – the internal engine that powers your business. Efficient operations are key to running a business that’s always getting better at what it does. By taking a look at how your business is run and asking yourself questions about existing processes, you’ll be able to define and optimize non-value adding parts of it. Lean Coaching is here to help make this process easier. ​

Key Elements/Terms

- KPI cascade
- Shopfloor management
- TPM
- Jidoka, Andon, 5S`
- Standardized work
- OEE
- Kaizen
- Suggestion scheme
- Visual management
- Manpower
- Capability development

Optimization in Supply Chain​

Optimization of The Business Process.

What is it?

Optimization of The Business Process that manages:​
- the physical flow of materials from suppliers to customers through the production and transportation processes.​
- the information flow from customers to suppliers through the processes of forecasting, planning and order management.​

Why is it important?

The overall target of the Supply Chain optimization is:​
 - to maximize the service level from the order to the final delivery to the customer;​
      ...while minimizing the inventories (Raw material, Work in Progress, Finished Goods);​
      …at minimum “total logistic cost."​

Key Elements/Terms

- SLead Time and Inventory reduction
- Kanban
- Volume Deployment
- Bottleneck Management
- Flexibility improvement
- OTIF deployment

Optimization in Maintenance​

Achieving zero breakdown with most effective and economical maintenance system via building process reliability and operation empowerment.

What is it?

Achieving zero breakdown with most effective and economical maintenance system via building process reliability and operation empowerment.​

Why is it important?

Maintenance system helps increase machine reliability, driving towards zero loss equipment that is operating at optimal cost:​
- Improvement of production output (zero failure, zero defect).​
- Competence building of maintenance technicians.​
- Equipment Reliability, Availability and Maintainability (RAM) increase.​

Key Elements/Terms

- Equipment availability
- Reliability Centered Maintenance
- Maintainability
- Maintenance cost

Assets as a Service​

Lean Coaching provides 3 levels of Services for the clients

What is it?

Lean Coaching provides 3 levels of Services for the clients:​
1. Technical Performance Service (TPS) – management of technical KPIs, technical availability, MTBF, MTTR, Operational Resolving Time​
2. Conversion Cost Service (CCS) – TPS plus spare parts, maintenance, output, manpower performance/productivity, facilities, utilities​
3. Operational Cost Service – CCS plus the external factors in production, supply chain, quality, human resource etc.​

Why is it important?

Focus on what your company can do the best - all the rest can be provided by Lean Coaching. Our company helps to expand the value and increase competitive advantage by outsourcing technical and operational activities to manage direct and indirect costs. ​

Key Elements/Terms

- Technical Performance Service
- Conversion Cost Service
- Operational Cost Service

New Product/Service Development and Introduction

The process of developing and introducing/ramping up new products or services into the Operations, the business considers core to satisfying customer expectations in existing or new markets or demands.

What is it?

The process of developing and introducing/ramping up new products or services into the Operations, the business considers core to satisfying customer expectations in existing or new markets or demands.​

Why is it important?

Competitiveness and thereby survival or growth of a business hinges on beating ‘the competition’ in terms of better satisfying customers in terms  of quality, cost and delivery speed (within the expectations of the Stakeholders). ​ ​

Key Elements/Terms

- ​Ideation/Business Case
- Prototyping
- Concurrent Engineering
- Stage-gated multi-level/multifunctional Project plans and execution and Lessons Learnt feedback (Keshikomi)
- VA/VE (Value Analysis / Value Engineering)
- OPL