Ten Reasons That Can Cause The Failure Of Even The Best Lean Improvement Plans

According to the top lean manufacturing consultants in India, incompetent and incapable team members are a major cause of policy failures. In some cases the incompetence might run deep into the management itself, which can prove to be an even greater problem. According to the lean manufacturing consultants in Delhi NCR, learning is the core of lean and continuous improvement. That is why it is important for organizations to treat every problem as a potential learning opportunity that encourages self learning, team learning and even organizational learning. Rather than creating a work environment where people are constantly guided by experts, it is important to allow them to experiment on their own and learn from their failures.

Ten Reasons That Can Cause The Failure Of Even The Best Lean Improvement Plans

Think Over Before Considering Lean Coaching Training Consultants

How does the consultant view the significance of individuals in comparison to the procedure part of changing the organization? How a time does your consultant spend to individuals and process? Many professionals identify the need to work on the people side, but have little to short time period organized to actually deal with the human part of the formula. This is where the client/consultant connection comes in and why you need to employ a friendly consultant. If you’re using Lean Tools successfully, your consultant will have no problems when it comes to multi-tasking on their daily obligations, to customers and your organization.

Think Over Before Considering Lean Coaching Training Consultants

The Different Features Of Lean Manufacturing For Better Business Growth

Lean manufacturing can be compared to a healthy diet plan that aims to make an organization faster, fitter and more competitive. It focuses on tightening processes, minimizing waste and steering the bottom line towards robustness. In other words, implementing the principles of lean manufacturing can help a business to turn into a high performer within its niche and thus naturally enhance its profit margins. This is ensured by eliminating wastage which might be in prevalent in various forms ranging from over-extended equipment setup to surplus inventory. It addition, the technique also proves beneficial in creating a flexible manufacturing process that not only helps to streamline but also speed up the timely delivery and product flow for the business.

The Different Features Of Lean Manufacturing For Better Business Growth

Key Parameters While Hiring The Services Of Lean Manufacturing Consultants India

The above factors make it quite clear that a good lean manufacturing consultant can help businesses attain a competitive edge and help them retain it in the long run. However, this objective can be achieved only if the consultants are able to adapt to lean manufacturing concepts that suit the specific needs of client organization. Most importantly the implementation of these principles should not lead to loss of job for any employees or changing the equation enjoyed by the business with its suppliers and clients. Rather the process should focus on ensuring that all of them work in sync with the business organization to deliver the final goods to the customers with greater value and maximum satisfaction.

Key Parameters While Hiring The Services Of Lean Manufacturing Consultants India

Understanding The Various Tools And Concepts That Form An Integral Part Of Lean Methodologies

Lean manufacturing is being increasingly adapted as an effective business approach by organizations across the globe. However, in order to gain the true benefits of using this technique it is essential for organizations to not only understand its purpose but also why they need to hire the services of professional lean consultants. According to the top lean manufacturing consultants in India, the primary objectives of this technique are to provide customer satisfaction, understand the value stream and continuously improve business processes. What makes the technique truly effective is that it provides the results by utilizing minimum resources by ensuring active involvement of the entire workforce in a continual process of improvement.

In this context, hiring the services of a lean manufacturing consultant is essential for ensuring the proper implementation of this technique. These consultants help the business organizations to understand how lean methodologies can help maximize productivity besides enhancing growth and profitability of the venture. This is ensured through the use of various tools and concepts that form an integral part of lean methodologies. Each of these tools and concepts offers a unique set of benefits and is implemented in accordance with the specific needs of the business organization.

Lean Concepts And Tools

There are many tools and concepts that lean manufacturing concepts comprise of. Each of the concepts has its own set of benefits, and is employed depending upon the requirements of a manufacturing unit. The six most critical of these tools and concepts are discussed in brief as follows.

Cellular Manufacturing

This concept focuses on the importance of arranging the various equipments and workstations in accordance with the different processes. It stresses on the location of these equipments in close proximity to groups of products produced in a similar manner.  The idea is to reduce the recycling time and inventories to help the business meet the market response deadlines.

Takt Time

Takt time is defined as the average time that a business should take for manufacturing a product or performing a transaction based on the needs of the customers and the working time provided. It is one of the most critical elements of lean manufacturing and is often referred to as the heartbeat of the customer. The lean coaching training consultants inform the trainees about using the following formula for calculating Takt Time.

Takt = T/D

Here T refers to the Time available for provision of a product or service and D is defined as the demand in terms of quantity.

Standardized Work

This concept refers to the process of documenting the description of methods, materials, tools and processing times required to meet the takt time for a specific task. The primary objective of this concept is to ensure the standardization of tasks throughout the value stream.

One Piece Flow Or Continuous Flow

This objective of this concept is to reduce the batch sizes to overcome any challenges resulting from system constraints. This principle focuses on producing a product or information by moving steadily from one value added processing phase to the next. This continuous flow of production not only minimizes any chances of delay in task fulfilment but also streamlines the entire manufacturing process.

Pull Systems And Kanban

The concept is used by customers to initiate the supply for manufacturing product as its demand increases. Kanban is the name given to the signals used within a pull system through integration of scheduling and travelling instructions. These signals are provided with the help of visual devices .such as containers and cards.

Quick Changeover/ SMED

Quick changeover is a 3-stage methodology that focuses on reducing the time taken for switching on a machine. It uses externalization and streamlining steps for minimizing changeover times to help reduce the batch sizes and maximizing just-in-time deliveries.