Lean Manufacturing Tools, Principles, Implementation services

lean manufacturing concepts

Lean manufacturing is also known as Lean enterprise or Lean production, Lean is a production and manufacturing practice that focuses on increasing customer value by reducing cost and production time by reducing or even eliminating waste and loss, Lean Manufacturing principles came from the philosophy of management in Japanese manufacturing, particularly from toyota’s production system (TPS).

Lean focuses on the disposal of seven types of waste:

1. Transportation
2. Inventory
3. Unnecessary and unproductive movement of “equipment and personnel”
   
4. Waiting times
5. Over–production
6. Unnecessary processing steps
7. Defect / Rework 

Lean manufacturing implementation roadmap

Arab Professional Academy experts can help clients to implement lean manufacturing principles, Drawing value stream mapping for several specific improvements, All of them were built on a strong model of personal development and change management to ensure the highest probability of success for sustainable change.

Benefits of Lean Production & Manufacturing

Lean Manufacturing consultancy includes a value stream mapping study, and evaluation the type of wastes and poor productivity efficiency (muda, Mura & Muri, subsequent optimization and 5S consulting).

Lean Manufacturing is a method and methodology for improvement, Focus on reducing the non-value added activities and processes and waste in production processes, Lean practitioners believe that if non-value-added activities are not reviewed in a process, 95% of the activities of this process will be of no-value added, In order to the enterprise might be able to survive and be able to improve profits, They have to look carefully at their operations and work to reduce non-value-added activities, And losses in its operational, manufacturing and logistics operations.

If the organization does not take a serious look at non-value added activities and waste in its operations, This may add new burdens to the business in increasing the costs and financial burdens on the company, The company might lost its ability to keep up with changes in the international markets and against competitors and increase the cost of the product and the price of its sale and the decrease of the company’s competitiveness, This may be a major reason for the business to exit the competition or the market as a whole.

The integration of Lean Manufacturing and Lean Six Sigma brings great benefits to companies in improving productivity, reducing problems and defects, and solving problems and negative issues in operations.

Work challenges that may be improved with Lean Manufacturing tools

• Many daily problems and the inability to find time to solve them
• The inability of the organization to carry out the increased customers’ orders
• Customer loss due to delays in delivery times
  
• There is a better way to operate and manufacture but not sure how or where to start?
• The cost of production increases faster than the company’s ability to raise the prices of selling products to customers

Why you should hire a consultant specializing in Lean Manufacturing

The desire to stay and continue: Companies will struggle to survive if current operations contain non-value added activities in their operations, The waste will increase cost and reduce productivity efficiency, Lean implementation is essential for the business to survive and achieve profitability.

Use an expert and focus on your core competence: The selection of Arab Professionals Academy team will ensure that you hire an expert consultants whom are able to solve problems in a systematic manner and within a specific time frame, We will help you in solving your problems while focusing on your core operations.

The customer expects this: Most customers will not choose you as a service provider if improvement and development methodologies such as Lean are not implemented in your business, In order to be able to get more customers and maintain existing customers lean has become critical

Gain the trust of partners, shareholders and stakeholders: Lean Manufacturing’s implementation and gain more profit should increases the confidence of shareholders, partners and stakeholders in the management system.

The customer experience will definitely improve: Lean Manufacturing’s consultancy ensures that a vlaue-added processes increased Lean implementation should always lead to a better customer experience. The best customer experience will always help you earn more money.

Inefficiency increases the cost of poor quality: The cost of poor quality is increased by inefficiency in this process. Using Lean tools, The facility can reduce deficiencies and reduce the costs of bad quality, Where the higher the quality costs, the higher the cost of the product and the higher the competition.

Lean Manufacturing tools

All consultants at Arab Professionals Academy for Training and Consultation have practical and professional experience in dealing with Lean Manufacturing implementation tools, including:

1. 5S
2. Andon
3. Bottleneck Analysis
4. Continuous Flow
5. Gemba (The Real Place)
6. Heijunka (Level Scheduling)
7. Hoshin Kanri (Policy Deployment)
8. Jidoka (Autonomation)
9. Just-In-Time (JIT)
10. Kaizen (Continuous Improvement)
11. Kanban (Pull System)
12. KPIs (Key Performance Indicators)
13. Muda (Waste)
14. Overall Equipment Effectiveness (OEE)
15. PDCA (Plan, Do, Check, Act)
16. Poka-Yoke (Error Proofing)
17. Root Cause Analysis
18. Single-Minute Exchange of Dies (SMED)
19. Six Big Losses
20. SMART Goals
21. Standardized Work
22. Takt Time
23. Total Productive Maintenance (TPM)
24. Value Stream Mapping
25. Visual Factory