Tier 1 - Operational Improvement
“In terms of return-on-investment, our engagement with Lean Coaching has paid for itself several times over in less than one year and is clearly one of the best investments we could have made.”
Lean Coaching was recommended to us by our largest customer as part of an effort to improve results, particularly on-time delivery at one of our largest manufacturing plants.
The process started with a detailed analysis of plant operations from order entry through shipping and billing by a talented team of Lean Coaches. This analysis gave a very good early indication that we had engaged with the right people. The analysis and subsequent action planning served to generate belief and engagement on the part of the plant staff and from that point forward we knew we were getting the traction necessary for success.
Weekly senior management updates quickly began to show two important outcomes, Results were improving across the board, Lean Coaching was coaching but the plant staff was doing the heavy lifting. Key plant metrics including labor efficiency, product quality, safety, scrap, and on-time delivery improved steadily throughout the time of Lean Coaching’s on-site presence but, far more importantly, they continued to improve as Lean Coaching wound down and ended their engagement. In retrospect the real value brought to Nelson Global Products by Lean Coaching was not in them solving our operational problems but in them giving our employees the tools and confidence to continue the progress on their own.
Batch Change Over & Minimum Job Role
“The coaches had very strong lean experience from manufacturing environments which made them able to quickly point to the root causes of our performance issues.”
In late 2014 we invited Lean Coaching to work together with us to support our performance improvement program. The objective was to improve batch change over times as well as to work with our first line & middle management team to be more focused on their roles on the shopfloor to drive a continuous improvement culture.
The coaches had very strong lean experience from manufacturing environments which made them able to quickly point to the root causes of our performance issues. Further, they were strong at building relations at the shopfloor which was key to securing ownership of actions within the organisation and hence ensure the success of the project.
During our partnership I have been particularly pleased about the energy that Lean Coaching helped me infuse in to the organization in order to change the mind-set and make people believe that targets can be met in a very challenging environment. The coaches were a real catalyst for making that happen. Because of this, other departments have since copied some of the same principles and tools to drive improvements.
Shop Floor Management Coaching
“I am confident that the LC coach was invaluable in achieving this through their drive, leadership and direction not only project based but interpersonal management of issues and people.”
Lean Coaching was recommended to us by our largest customer as part of an effort to improve results, particularly on-time delivery at one of our largest manufacturing plants.
The process started with a detailed analysis of plant operations from order entry through shipping and billing by a talented team of Lean Coaches. This analysis gave a very good early indication that we had engaged with the right people. The analysis and subsequent action planning served to generate belief and engagement on the part of the plant staff and from that point forward we knew we were getting the traction necessary for success.
Weekly senior management updates quickly began to show two important outcomes, Results were improving across the board, Lean Coaching was coaching but the plant staff was doing the heavy lifting. Key plant metrics including labor efficiency, product quality, safety, scrap, and on-time delivery improved steadily throughout the time of Lean Coaching’s on-site presence but, far more importantly, they continued to improve as Lean Coaching wound down and ended their engagement. In retrospect the real value brought to Nelson Global Products by Lean Coaching was not in them solving our operational problems but in them giving our employees the tools and confidence to continue the progress on their own.
Jishuken and Kaizen
“I believe the true benefit of our working with Lean Coaching has been lighting the fuse on our continuous improvement culture, the ultimate benefit of which has yet to be seen.”
The benefit we’ve received to date from our association with Lean Coaching can be categorized into 2 areas – improvement in bottom line results and a change in our behavior. Both were a result of actually having to do for ourselves while being coached along the way.
The tangible results in safety, quality, and efficiency were achieved through the application of lean tools, many of which we “knew” but had yet to understand until we were actually guided through using them by Lean Coaching. The change in our behavior has been based on a change in our underlying thinking.
Lean Coaching has helped us grasp the concept of understanding, or defining, the “standard” before effective problem solving or improvement can happen. With their guidance, we have evolved to applying PDCA thinking in problem solving, developing robust processes, focusing on confirmation by management, and coaching employees for development and engagement. I believe the true benefit of our working with Lean Coaching has been lighting the fuse on our continuous improvement culture, the ultimate benefit of which has yet to be seen.
Manufacturing Concepts
“The shared ownership of each Plants targets between LEGO and LC worried well with an excellent overall result of 95% for the project KPI s. I am pleased with both the results and process provided by LC and I am sure this will help inspire us in our future lean activities.”
In 2010, increased market demand was at risk of exceeding our capacity and we needed to find a way to increase this but without risk to our Safety, Quality & Cost results. The approach was clear – to accelerate our Lean activities, but how to execute swiftly and reliably?
Lean Coaching have been our preferred suppliers of Lean expertise since 2008 and together we have collaborated on many projects to optimise both results and lean leadership competencies. Therefore we engaged their support in this project named “Performance Acceleration”.
Simultaneous projects were launched in our Czech Republic and Mexican plants with two clear objectives:
- Ensure that each Plant achieves their Safety, Quality, Delivery, Cost & People Targets for 2010.
- Accelerate the implementation of the Global Lean Tools through the coaching of senior managers and internal lean consultants
I attended the kick off for the Mexico project and was impressed with the approach taken and the speed at which LC immediately got the plant into implementation mode. Both projects followed a standardised approach: Assessing and judging the Plants Capability to achieve their KPI’s, placing immediate action plans upon Red rated items and using Tactical Implementation Plans to move from current to future state in the implementation of the lean tools.
Overall, the project objectives were well managed and it was pleasing to see both the effects upon the KPI’s and also the Leadership behaviours in the Plants. The shared ownership of each Plants targets between LEGO and LC worried well with an excellent overall result of 95% for the project KPI s. I am pleased with both the results and process provided by LC and I am sure this will help inspire us in our future lean activities. Please do not hesitate to contact me for detailed feedback or further recommendation.
Visual Management Deployment Project
“The implementation proved very successful not least thanks to the professional expertise and flexibility to find suitable solutions. Grundfos A/S have benefitted substantially from the effort provided by LeanCoaching.”
In 2011 LeanCoaching was invited to support Grundfos A/S. The task was generally about supporting the delivery of a major product development project on time and within budget. Legislation defined a sharp deadline and failure to meet this was not an option. During this effort LeanCoaching co-developed a concept of implementing visual management and general lean methodology in a customized project execution setup suitable for Grundfos A/S.
The project was delivered on time. Not least thanks to the support by LeanCoaching. Afterwards LeanCoaching participated as subject matter experts in other key projects and the global roll out of the concept as a new standard primarily facilitating the daily coaching of key change agents on three continents. The implementation proved very successful not least thanks to the professional expertise and flexibility to find suitable solutions. Grundfos A/S have benefitted substantially from the effort provided by LeanCoaching.
Lighthouse Project
“Lean Coaching demonstrated a unique skill above any other consultant group I’ve ever been exposed to. From day 1 of the project we were taught to be self supportive with a new vocabulary, a new way of thinking and a new approach to continuous improvement. Lean Coaching scores an A+!”
For myself and I believe the rest of this plant, the Lighthouse project was more of a transformation. This “Lighthouse project” could easily be a one time investment and a one time event, withering away after the Lean Coaching support has left.
Lean Coaching demonstrated a unique skill above any other consultant group I’ve ever been exposed to. From day one of the Lighthouse project we were taught to be self supportive with a new vocabulary, a new way of thinking and a new approach to continuous improvement. Lean Coaching helped us construct a Lean Management foundation and this foundation is absolutely essential to effectively leverage any Lean Manufacturing tool. The success of any organization such as Lean Coaching should be measured AFTER you leave the client on their own to carry forward with the knowledge and tools they acquired. Lean Coaching scores an A+!
Shop Floor Management
“Major benefits came not just from KPI improvement but also the interdisciplinary team work on improvement projects, we learnt not to wait for a crisis in order to work together & by implementing lean activities, the results follow automatically.”
Straumann is a world leader in a very dynamic market our production plant is used to undergoing changes, we were fit but wanted to start a journey towards excellence. Initiatives to push lean techniques were only locally successful, but the achieved improvements prompted us to make a global roll-out.
With the initiative coming from the plant and not from the Corp. organisation, the SFM project was used as a catalyst to provoke major changes & started from a very favourable position with dedicated people who wanted to drive the company forward.
Major benefits came not just from KPI improvement but also the interdisciplinary team work on improvement projects, we learnt not to wait for a crisis in order to work together & by implementing lean activities, the results follow automatically.
I’m convinced about the LeanCoaching approach, they used very professional & skilled coaches to support us on our journey, not only bringing sound lean knowledge and experience, but also real social & personal competencies, showing clear, strong leadership in our project. This was a winning factor in our project as the people trusted the direction & wanted to follow.
Roll-Out Program
“I am confident that the LC coach was invaluable in achieving this through their drive, leadership and direction not only project based but interpersonal management of issues and people.”
At the end of 2008 Tarkett, the world leader in research, development, manufacturing and salesof integrated flooring solutions, decided to become the benchmark in Quality, Service, Costs and Innovation.
Hence, the implementation of a “World Class Manufacturing” program was started early in 2009.After a tendering exercise Lean Coaching was selected to help us in the roll-out of this program. Throughout the process, Lean Coaching demonstrated a clear commitment to the program. Their excellent coaching has enabled us to secure the successful roll-out of the program worldwide. By the end of 2010 already 13 out of 29 plants had started with the implementation of the program.
Good progress has already been made and considerable further improvement potential has been identified. The knowledge and skill of Lean Coaching in this field is remarkable, their customerfocus, commitment and result orientation is second to none. Without the focused support of Lean Coaching I am certain that we would not have been able to achieve our implementation and successful results in such a short time frame.
Tier 1 – Lean Transformation Project
“Regarding to results, what I can comment on is that they were extremely satisfactory, and it was decided to carry out the implementation for the whole plant.”
Our factory was chosen for a Lean Transformation process, where our goal was to improve results through the implementation of the MAHLE Production System. The goal was to achieve sustainable results for our organization, reducing systematically our wastes. We assign a multidisciplinary team composed by several departments of the company. We seek the support of Lean Coaching, who was an outstanding partner to support our Lean transformation process. We carried out a detailed diagnosis of the current state of the factory and used Hoshin Karin workshop to define our true north. After defining the vision with the support of Lean Coaching specialists, we created our Master Project Plan (MPP), aligned with the search for zero defects, high quality, lower cost, with the shortest deadlines and with a clear focus on adding value to our customers. Lean Coaching team support was fundamental, since many changes (alteration or creation of standards) would begin to require a new mindset for the entire team. How did we make it all work? We had a standardized routine on a daily basis to support all of our activities and manage to evolve in an organized way. Our meetings were at our information centre composed by Shop Floor Management (Regular communication, Process Confirmation and Structured Problem Solving) and Obeya. This whole methodology was very well succeeded, since we invested on people development through Sensei Coaching approach (behavioral change). Regarding to results, what I can comment on is that they were extremely satisfactory, and it was decided to carry out the implementation for the whole plant. All the results achieved are a natural consequence of this well-defined decision made by MAHLE, as well as the result of the support and active participation of the Leadership team.
Lean Transformation Project
“As a result, we have more competent, involved and loyal people to go further to our Transformation road. These results allow us to recommend Lean Coaching with confidence.”
8 months of cooperation between Lean Coaching consultants and our development department team have resulted in established capability of solving complex-task, high-level expertise in multiple issues, and all this within very limited and very constrained and pressing time-frame within constantly changing circumstances. With very small amount of change agents (on average there were about 15 people for all activities including business system implementation and working over initiatives) and just 2 consultants we managed to cover more than 1200 production people and lead them to better operational and motivational practices. As a result, we have more competent, involved and loyal people to go further to our Transformation road. These results allow us to recommend Lean Coaching with confidence.
Detroit Diesel Operations
“Lean Coaching has been key to developing our lean Journey at Detroit, Transforming Performance in our Production areas.”
Lean Coaching has been key to developing our lean Journey at Detroit, Transforming Performance in our Production areas.
Their designated expert coach understood our need and designed an Improvement Strategy based on gap analysis and assessments. Focusing to Practical Problem techniques, they worked to coach our Managers and Leaders with Lean tools and behaviors to drive performance across the organization, in turn producing a robust and sustainable platform ready for our next step forward along with the cost savings that were generated.
Lean Coaching are highly recommended!
Focused Improvements
“The project’s goal of reducing costs was achieved, staff involvement was increased, and over 75% of employees were trained in Lean tools.”
Over 2 years of cooperation Lean Coaching consultants have established themselves as high-level experts, capable of solving complex tasks for a limited time in large-scale projects, coordinating processes with the participation of large project teams, including 60 agents of treason and with more than 600 people in production aria. The project’s goal of reducing costs was achieved, staff involvement was increased, and over 75% of employees were trained in Lean tools. These results allow us to recommend “Lean Coaching” with confidence.
Benchmark
“The results of our close cooperation with Lean Coaching Ltd. Showcase the efficiency of applying our techniques by enterprises.”
The results of our close cooperation with Lean Coaching Ltd. Showcase the efficiency of applying our techniques by enterprises. We look forward to our fruitful cooperation within the implementation of the Lean Production Project in the Republic of Tatarstan.
(Republic of Tatarstan)
Lighthouse Project
“Thanks to a highly professional approach of the lean coaches our change agents that they trained are now capable of applying and deploying lean principles across the whole company.”
Analyzing the results of the joint project “Lighthouse”, Trade Group “Izhtrading” express their gratitude to your team for effective implementation and roll-out of lean-techniques and lean-thinking. Thanks to a highly professional approach of the lean coaches our change agents that they trained are now capable of applying and deploying lean principles across the whole company.
Lighthouse Projects
“Your professionalism as a lean-manager, rich knowledge and vast practical experience allowed KAMAZ to reach new step in Production System Development.”
Your professionalism as a lean-manager, rich knowledge and vast practical experience allowed KAMAZ to reach new step in Production System Development.
During the project lifetime we’ve become one team, aimed on common goal. The goal is reached, project is completed, but our partnership continues, new achievements are waiting for us!
Lighthouse Project
“A continuous improvement culture is cascaded top down, all the way to the level of operators, and is gradually becoming an integral part of life in the whole company.”
Within these few years, all-encompassing improvement activities were carried out in laminating area, het treatment, insulated glass assembly, cutting etc., which included 5S, standardized work, process re-balancing, training operators, brigadiers, group leaders and production managers in planning their daily activities as per their minimal job role.
Currently we have a self-training team capable of monitoring the process status, prioritizing, detecting and solving top problems, as well as developing people of their own department / area. A continuous improvement culture is cascaded top down, all the way to the level of operators, and is gradually becoming an integral part of life in the whole company.
Business System and Production Culture Transformation
“One of the most important tools is coaching of managers, through whom the right behaviours get cascaded to all the levels down and sustainability of changes is achieved.”
Consultants have implemented a new performance management system in production departments, which ensures transparency of the processes, involvement of all the relevant departments, clear and effective communication, prompt and accurate decision-making process, as well as clear and simple escalation procedure. Sustainability of changes is ensured via personnel involvement and problem-solving tools – “A3 problem solving” and some others. One of the most important tools is coaching of managers, through whom the right behaviours get cascaded to all the levels down and sustainability of changes is achieved.
Shop Floor Management Coaching
“I am very pleased with our collaboration and we as an organization wouldn’t have been able to do achieve what we achieve today if it wasn’t for the support and guidance we have received throughout our journey together with Lean Coaching.”
NNPII has worked together with Lean Coaching for more than 5 years within different aspect of the manufacturing operation, adopting lean principles targeting improved product quality, process stability, delivery performance and employee engagement.
Today we see significant impact in all our business areas and we are right now harvesting the benefits from our intense and focused efforts guided by Lean Coaching. All improvements we see today are fundamentally linked to a change in our thinking and acting way as leaders. Our new way of managing is built on the lean philosophy which Lean Coaching enlightened us and coached us in embracing. Our thinking way resonates throughout the organization through our continuous improvement mind-set and shop floor involvement.
I am very pleased with our collaboration and we as an organization wouldn’t have been able to do achieve what we achieve today if it wasn’t for the support and guidance we have received throughout our journey together with Lean Coaching.
Shop Floor Management
“The success of SFM in our Factory is based on the Coaching approach, which allowed us to get the necessary mindset of our Senior Management. Furthermore by coaching-the-coach we established a system that made sure, to get the right thinking through the whole hierarchy within our organization.”
Having been involved in Lean activities as part of the Siemens Production System (SPS) team here in Zug we felt the need to have a more coordinated level of activities based on building a successful company and decided to implement SFM. Considering the success of the activities in Factory Volketswil and the goal to standardise SFM within our Factories, we again chose Lean Coaching to be our guide for the project here in Zug. Using their in-depth knowledge of Lean and especially in our case SFM allowed us to understand and implement it’s tools, theory and application. The system of day to day managements allowed us to visualise, stimulate and challenge improvement in all areas. By defining our goals using “Hoshin Kanri” we were able to set out our objectives and align it to our resources using the “Tactical Implementation Plan”, thus enabling the visualisation and tracking of the daily goals to be seen and managed on the shop floor. This allowed the whole team to be able to clearly understand their roles and activity in the introduction of SFM onto their areas using KPI (Key Performance Indicators) to visualise and maintain the momentum of the project.
Underpinning SFM was the use of PPS (practical problem solving) using A3 and PDCA allowing us to see from our own data the variation from the plan, analyse the problems through the A3 or PDCA and using this as a tool to develop the workers as well as the leaders in solving the problems we had been living with on a day to day basis. Their use of real Toyota based knowledge (using ex managers with extensive knowledge of the Toyota Production System) is invaluable both because they know the system and also because they have lived and breathed it.
The success of SFM in our Factory is based on the Coaching approach, which allowed us to get the necessary mindset of our Senior Management. Furthermore by coaching-the-coach we established a system that made sure, to get the right thinking through the whole hierarchy within our organization.
Shop Floor Management
“Their ability to share their “concrete” knowledge by a strong and personal involvement with our people was demonstrated through significant productivity improvements in a short term (KPI’s –OPR & FTT).”
On a LEAN journey you have some steps from the beginning. To find a partner like LeanCoaching was a key element for our success. To see the huge difference between consulting and coaching is so easy with this partner that we can say that it was a chance for all of our Directors & Managers to be supported on shop floor.
If our thinking way wasn’t clear before our collaboration with LeanCoaching, it is now as we are able to talk about the key elements for our development, for example; Blue sky, Hoshin Kanri, Tactical Implementation Plan’s, etc.
The huge strength of this team is to provide natural, advice and expertise on how to improve performance based on their many years of operational experience and best practices. Their ability to share their “concrete” knowledge by a strong and personal involvement with our people was demonstrated through significant productivity improvements in a short term (KPI’s –OPR & FTT).
The success of our future will be ensured not only by tools and techniques that were directly applicable and delivered sustainable improvements, but also through the new thinking and mind-set on continuous improvement.
Shop Floor Management
“LC has been able to execute change in many different and difficult sectors of the business, and in both senior and shop floor situations. Their positive enthusiasm allied to their drive and passion makes them a world class agents of change.”
Lean Coaching provided great guidance and direction for the business during the time we spent with them. they also gave us support when required and openly shared their Lean knowledge and experience.
Any kind of issues and difficulties were easy to address with their support.
LC has been able to execute change in many different and difficult sectors of the business, and in both senior and shop floor situations. Their positive enthusiasm allied to their drive and passion makes them a world class agents of change. They are able to listen actively and assimilate information before driving through to deliver results. They build up relationships extremely quick and people trust them almost by default.
LC are passionate consultants, whose enthusiasm enables them to deliver where others may fail. They are curious and inquisitive and always look for the root cause of issues and problems. Working with them has been a pleasure and their positive attitude and sense of humour make it enjoyable even under pressure.
We have no reservations in recommending Lean Coaching, and would be happy to work with them again anytime.
Tier 1 – Expert Training
“The program had a very good effectiveness, once new projects were naturally defined by the area leaders and experts’ team have been able to support a sustainable operational improvement.”
Lean Coaching was a great partner supporting our journey to develop our Lean Culture.
To develop our experts’ team is an important strategy to create the momentum to keep the knowledge, the concepts and spread the tools and core competencies to assure a sustainable Lean Journey.
Since the beginning a wide operational and people assessments were done to define a good diagnosis. Then, the projects were defined in common sense and the training processes were well organized and followed. Lean Coaches are an essential part of trainees’ development.
MPS experts are currently well prepared to apply methods and tools, to act as change agents also regarding lean behaviors according to our strategy. I can say that the program had a very good effectiveness, once new projects were naturally defined by the area leaders and experts’ team have been able to support a sustainable operational improvement.
Financial results are natural consequence of this well succeeded decision taken by MAHLE.
Shop Floor Management Coaching
“I am very pleased with our collaboration and we as an organization wouldn’t have been able to do achieve what we achieve today if it wasn’t for the support and guidance we have received throughout our journey together with Lean Coaching.”
NNPII has worked together with Lean Coaching for more than one year adopting lean principles targeting improved product quality, process stability, delivery performance and employee engagement.
Today we see significant impact in all our business areas and we are right now harvesting the benefits from our intense and focused efforts guided by Lean Coaching. Our journey together with Lean Coaching has in many ways been a radical paradigm shift and a new way of managing our operation. All improvements we see today is fundamentally linked to a change in our thinking and acting way as leaders. Our new way of managing is built on the lean philosophy which Lean Coaching is embracing.
I am very pleased with our collaboration and we as an organization wouldn’t have been able to do achieve what we achieve today if it wasn’t for the support and guidance we have received throughout our journey together with Lean Coaching.
New Product Introduction and Ramp-up
“Throughout the entire period we have been successfully assisted from Lean Coaching. The results have been remarkable.”
In the summer of 2009 we were challenged with a factory retrofit for a new device product to be done as fast as possible. The change included more than 50 new machines from 180 tons moulding machines to high-speed automated assembly lines. The change included an organizational retrofit in both competences and mind-set.
Throughout the entire period we have been successfully assisted from Lean Coaching. The results have been remarkable. Not only have we made the entire technical retrofit including ramp-up but we have also changed the mind-set of all production employees seamlessly through the process. Through relentless focus on lean thinking we have started a journey towards a production army of scientists that can sustain our improvements.
Lighthouse Project
“Some years ago my team and I worked successfully in a project with Lean Coaching in a production environment. Two years later this success was even acknowledged with an award by a leading business magazine.”
After taking the management responsibility of a highly service oriented operation with 1200 employees my team and I have adopted lean principles from our experience in production. After the intense daily work with LEAN COACHING we have been able to convince our staff of the advantages of these principles which led to a change in our culture in various ways.
and Operational Services
Shop Floor Management
“The success or SFM is based on the skill and ability within Lean Coaching who having years of practical application in some of the most progressive lean companies, living it day in, day out, who have now given over to sharing this solid skill and knowledge with the rest of us.”
In todays demanding production environment you need the ability to be dynamic and creative, based on a core concept of giving the customer what they want and this is why we chose Lean Coaching to be of support in this project.
Their in-depth knowledge of Lean especially in our case SFM, it’s tools, both theory and application of day to day managements systems both visualise, stimulate and challenge improvement. With the use of “Hoshin Kanri” we were able to set our vision and then put it into tangible time based management with the “Tactical Implementation Plan” enabling the cascade down of the overall company goals to be seen on the shop floor. This meant we were all working and facing the same challenges but knowing we had the support and direction from the whole management team leading to significant improvements in quality, safety, productivity, cost & the development of our people through the use of KPI (Key Performance Indicators).
This was then augmented with the use of PPS (practical problem solving) using A3 and PDCA allowing us to be able to find, visualise and then solve the problems we had been living with on a day to day basis freeing up our time to meet the new challenges that were created.
The success or SFM is based on the skill and ability within Lean Coaching who having years of practical application in some of the most progressive lean companies, living it day in, day out, who have now given over to sharing this solid skill and knowledge with the rest of us. This does not just lie on the shop floor but right through the business, coaching the management chain at all levels of the organisation.
