Establish a Lean Management System by implementing measures on-site (Gemba)

Based on our many years of experience with customers worldwidewe have learned that many companies have difficulty establishing the lean management system sustainably.

It is clear from the start that Lean is management's business! The management itself must display a clear commitment in order to be able to lead the various departments in the "way" of lean. As a first step this includes questioning the existing standards of all processes, new standards are defined and everything is continuously optimized. It is also an important management task to monitor compliance with established standards. Furthermore, management must not only "carry the employees" but also involve them in the lean process.

We help you create this understanding in management and roll out the lean management method in the respective departments both productively and administratively.

 

Our approach:

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1. Assessment of the potential


  • Interview top management in order to understand wishes and objectives for lean production.
  • Factory tour to observe the current level of process flows and methods and assess the improvement potential.
  • Introduction of the KPC consulting method. 
  • Afterwards you will receive our cost offer for a current-state analysis and the implementation workshops.
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2. Current-state analysis and action plan


Our on-site analysis usually takes 2-5 days, depending on the company size, and includes:

  • Analysis of the company key figures (previously requested)
  • Factory visit
  • On-site process observation and analysis
  • Decide on the consulting method and steps to introduce the lean management system.
  • Creation of an implementation plan
  • Quantify and agree on objectives
  • Presentation to management
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3. Implementation workshop


  • Together with representatives of the individual departments, processes and methods are questioned on-site and optimised using the new improvement measures.
  • Fast and gradual implementation of measures along the entire value-added chain: by harvesting the "low-hanging fruits", the lead time can be significantly reduced within the first year.
  • To further reduce costs we focus on increasing the productivity of various processes from the end of the value-added chain backwards.
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Everybody at the same table

Irrespective of their position within the company, all participants work as a team to develop practical solutions for increasing efficiency together with the KPC lean consultant. The participation of members from top management is very important in order for them to understand the value creation processes on-site and keep decision-making processes short.

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