Lean Methodology

Lean Methodology

Adopt Lean Paradigm
Default Value
Identify Value Stream
Design Production System
Implement Flow
Implement Total System Pull
Strive for Perfection


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, with the result being an improved competitive position for your organization through the reduction of waste.

Surtel Philosophy

Our implementation approach is a very structured methodology and the basis for our blueprint for covering all phases of the project. We use an eight-phase approach that can be tailored to your specific needs.

Phase 1 - Adopt Lean Paradigm

  • Build vision
  • Establish need
  • Foster lean learning
  • Make the commitment
  • Obtain senior management buy-in

Phase 2 - Prepare

  • Integrate with enterprise level
  • Establish Lean Operations implementation team(s)
  • Develop implementation strategy
  • Develop a plan to address workforce changes
  • Address site specific cultural issues
  • Train key people
  • Establish target objectives (metrics)

Phase 3 - Default Value

  • Select the initial implementation scope
  • Define Customer
  • Define value Quality, Schedule and Target Cost

Phase 4 - Identify Value Stream

  • Record current state value stream
  • Chart product and information flow
  • Chart operator movement
  • Chart tool movement
  • Collect baseline data

Phase 5 - Design Production System

  • Develop a future state value stream map
  • Identify task time requirements
  • Review make/buy decisions
  • Plan new layout
  • Integrate suppliers
  • Design visual control system
  • Estimate and justify costs
  • Plan TPM (Total Production Maintenance) System

Phase 6 - 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 cell layout
  • Implement visual control

Phase 7 - Implement Total System Pull

  • Select appropriate production system control mechanism
  • Strive for single item flow
  • Level and balance production flow
  • Link with suppliers
  • Draw down inventories
  • Reassign people
  • Re-deploy/dispose assets

Phase 8 - Strive for Perfection

  • Team development
  • Optimize quality
  • Institutional 5S (sort /set in order / shine / standardize / sustain)
  • Institute Kaizen events
  • Remove system barriers
  • Expand TPM
  • Evaluate against target metrics
  • Evaluate progress using Lean maturity matrices