Lean Methodology

Lean Methodology

Introduction

Lean transformation helps to create a value stream throughout the supply chain by eliminating waste. Lean techniques focus on processes and managing the efficiency of those processes. The result is an improved competitive position for your organization through the reduction of waste.

Surtel’s Philosophy

Our implementation approach is a very structured methodology that we have executed in the past and is the basis for our blueprint for covering all phases of the project. We use an eight-phase approach that can be tailored to our client's specific needs.

PHASE 01 - Adopt Lean Paradigm
  • Build a vision
  • Establish need
  • Foster Lean learning
  • Make the commitment
  • Obtain Sr. Mgmt buy-in
PHASE 02 - Prepare
  • Integrate with Enterprise Level
  • Establish Lean Implementation Team(s)
  • Develop Implementation Strategy
  • Develop a plan to address workforce changes
  • Address site-specific cultural issues
  • Establish target objectives (metrics)
PHASE 03 - Default Values
  • Select initial implementation scope
  • Define Quality, Schedule, Target Cost
  • Define Customer
PHASE 04 - Identify Value Streams
  • Record the current state value stream
  • Chart product and information flow
  • Chart operator movement
  • Chart tool movement
  • Collect baseline data
PHASE 05 - Design Production System
  • Develop a future state value stream map
  • Identify task time requirements
  • Review make/buy decisions
  • Plan a new layout
  • Integrate suppliers
  • Design a visual control system
  • Plan Total Production Maintenance System
  • Estimate and justify costs
PHASE 06 - Implement Flow
  • Standardize operations
  • Mistake proof processes
  • Achieve process control
  • Implement TPM
  • Implement self-inspection
  • Eliminate/reduce waste
  • Cross-train workforce
  • Reduce set-up times
  • Implement visual controls
PHASE 07 - Implement Total System Pull
  • Select the appropriate production system control mechanism
  • Strive for single item flow
  • Level and balance production flow
  • Link with suppliers
  • Drawdown inventories
  • Reassign people
  • Re-deploy/dispose assets
PHASE 08 - Strive For Perfection
  • Team development
  • Optimize quality
  • Complete Concentration
  • Evaluate progress using Lean maturity matrices
  • Remove system barriers
  • Expand TPM
  • Evaluate against target metrics
  • Institute Kaizen events
  • Implement VC
  • Evaluate against target metrics