What is Lean Implementation?

Lean Transformation is a form of change. It involves the transfer or realignment of a company or department, from an old to a new state. Lean Transformation focuses on strategies, objectives, structures, and features of Lean companies and systematically applies Lean management methodologies and tools.

However, Lean Transformation is more than a ‘tool box’ from which you can make an ad-hoc selection in order to optimize stand-alone subprocesses without keeping in mind the big picture. Instead, it is a holistic concept, a business culture, and management approach which turns companies and value networks into more efficient and less waste-affected entities which leads them towards Top Performance.

On their way to the lean organization , companies go through several stages:

  • The Status Quo Phase
  • The Pre-Change Phase
  • The Change Phase
  • The Continuous Improvement Stage

The Status Quo Phase is the phase that actual processes their outcome and related costs are reviewed this we call the operations due diligence and the bases to identify potentials and potential costs savings.

The pre-change phase is characterized by the existence of traditional, functional processes with a high degree of optimization potential.

The actual Transformation begins with the change. This phase brings about profound modifications of processes and procedures, which might result in new challenges for the company even if the overall objective is to achieve substantial structural improvements, in the long run, the beginning of the Transformation might create a feeling of destabilization within the company.

Once the change has successfully been accomplished, the company enters the stage of continuous improvement, which is marked by continuously or indefinitely taking optimization and stabilization measures. Lean transformation and the Lean idea should not be considered as ‘initiatives’ or ‘projects’ – both of which imply an end date instead of the continuous pursuit of improvement. It is this motivation, shared by all management line, middle, executive and Board and all employees, which differentiate successful from less successful companies.

One of the lean concept targets is elimination of waste!

At AMC we categorize waste into obvious waste and hidden waste.

As contrary to value creation waste include all activities that, from a customer standpoint, do not add value to a product. Obvious waste should be eliminated, hidden waste can only be minimized.

AMC also divided waste into seven types:

  • Overproduction (more parts are produced than currently needed)
  • Inventory (including raw materials and purchased components)
  • Scrap (not optimized BOM or BOO)
  • Overprocessing (processes not adapted, e.g. processes, reworks)
  • Transportation of Material
  • Motion of employees within the workflow
  • Waiting times for employees

It is important to look and consider in all planning the order how these types of waste are listed as overproduction is the worst type of waste and as result create the other types of waste.

Planning of or Transforming to the LEAN Factory

Doing the right things at the right place at the right time and foremost with the right people

With changing market challenges and increasing global competition, manufacturing companies must dramatically reduce lead time to customer orders and new customer demands in order to gain, or retain, competitiveness. Taking the right decisions on the stage of global businesses is a difficult challenge that requires reliable partners with good know-how of the local situation, practices, and habits – both in Asia and worldwide.

With over two decades of experience in China and Southeast Asia as well as a strong network of partners, we can provide the necessary support and advice in order to make the right decisions and develop and implement successful strategies for your operations.

Since establishing our company, we have been successfully developing and implementing Lean Factory transformation. Our expertise in different industries across Asia and globally offers combined over 50 years of experience that will support you during the localization as well as the development of your operations. The commitment to Lean principles guarantees efficiency as well as transparency from finding a suitable location for production in case of relocation or extension of your operations footprint to the efficient transformation of the manufacturing operations and supporting processes.

Lean Transformation and Management

The success of a Lean transformation at your company stands and falls with the mindset and performance of your managers. With the help of our training program for employees and  Lean champions, you can develop your own in-house Lean Leader to pave the way to top performance in the area of responsibility. The Lean Leader guarantees that Lean method competence will be sustainably anchored at your company. The Lean champion sets the course and creates the structure needed for optimal collaborative work while also encouraging and demanding continuous improvement. By helping employees become qualified, Lean champions assist them as they learn and develop.

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