Lean is a business system for organizing and managing operations, suppliers and customer relations. Manufacturers and other organizations use Lean principles, practices and tools to create customer value - goods and services with higher quality and fewer defects - with less human effort, less space, less capital and in less time than the traditional system of batch and queue/mass production.
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Lean Manufacturing is the application of principles and tools to optimize your manufacturing operations and meet the demand of your customers while increasing your profitability. Non-value added or wasteful practices can lead to overproduction, excess inventory, defects, underutilized people, excess processing, motion and transportation.
Lean Manufacturing's benefits include the reduction/elimination of waste, fewer defects, shorter lead times, increased manufacturing capacity, lower production costs, inventory reduction, increased on-time delivery and improved customer satisfaction.
The same Lean principles and tools utilized in manufacturing operations can be applied in the office or administrative processes. Office wastes can manifest in excess paperwork, redundant approvals, inefficient work area design/layout, incomplete or inaccurate information and complex tracking systems.
Accurate estimating, efficient order handling and responsive customer service help to protect your profits, maintain your reputation and keep you competitive.
Lean Distribution is specifically targeted for those in the warehousing and distribution industries who desire to improve efficiencies in their warehouse and distribution operations using the Lean methodology of waste elimination.
The Five S program focuses on having visual order, organization, cleanliness and standardization. The results you can expect from a Five S program are: improved profitability, efficiency, service and safety. The principles underlying a Five S program at first appear to be simple, obvious common sense. And they are. But until the advent of Five S programs many businesses ignored these basic principles. The benefits from implementing 5S include improved Safety (preventing accidents), increased Productivity (eliminating wastes), higher Quality (preventing errors), and more machine uptime (reduction in breakdowns).
Total Productive Maintenance
Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.
TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. Downtime for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.
Typical manufacturing operations have experienced improvements in the following areas in a relatively short period of time (6-12 months) through the implementation of TPM:
- Overall Equipment Effectiveness (capacity) improvement of 25-65%
- Quality improvement of 25-50%
- Maintenance expenditure reductions of 10-50%
- Percent planned vs. unplanned maintenance increase of 10-60%