Lean OpEx program supports implementation of continuous improvement principles. Through constant process improvement, waste elimination and usage of proven methods and tools, we are able to deliver significant benefits.

CUSTOMER’S BENEFITS FROM LEAN PRINCIPLES IMPLEMENTATION

Benefits form implementing Lean Manufacturing program

Productivity improvement ? through continuous waste elimination, we can achieve from 20 to 80% productivity improvement.

Inventory reduction ? Just in Time and Just in Sequence deliveries and Kanban and Milkrun implementation, can cause inventory reduction up to 50%.

Lead Time reduction ? continuous flow implementation, balanced work, simplification and synchronization of the processes, can shorten Lead Time about 50% or even more.

Failures reduction ? reorganization of work places through implementation of 5S principles, standard work and usage of quality methods at the source (Poka Yoke, Andon), can lead to failures reduction up to 80.

Deliveries punctuality improvement ? appropriate planning and production leveling methods, short changeover times and producing in small batches, can significantly improve punctuality of customer deliveries. In our projects, we can achieve even an 50% improvement in this area.

Space reduction ? line design, layout optimization, focusing on the flow, inventory and unnecessary process elements reduction, allow us to reduce production/warehouse area up to 60%.

Downtime reduction – thanks to TPM and autonomous maintenance tools, our Clients are able to reduce downtime up to 70%.

REQUIREMENTS FOR ACHIEVING FINAL SUCCESS ARE:

  • An involvement and support from the highest management on every organizational level
  • The connection between objectives of the implementation project and organization’s business goals
  • Dedicating proper resources to the implementation work
  • Building required skills within the company

Usually, Lean implementation requires a change in existing ways of doing the job. Simply applying tools is not enough to achive final success. We need to create an appropriate management system, that will support Lean tools and principles.

TYPICAL LEAN PROGRAM ELEMENTS

  1. Process analysis
    After establishing project goals, we conduct initial state analysis. Using proven methods (e.g. Value Stream Mapping, Spaghetti Analysis for materials and operators), we can identify possible improvements and choose proper tools, which will be used in the project.

  2. Implementation project preparation
    In this stage, we create a project team, plan project course in details and establish, how to monitor achievements. We conduct initial trainings for the management group and project team and define the scope of internal skills development.

  3. Bespoke trainings and workshops for every level in the organization
    OpEx Group offer includes: trainings for the highest management, hard skills trainings (e.g. 5S, one-piece flow, SMED) oraz soft skills trainings (e.g. Leadership role in continuous improvement process, Training Within Industry)

  4. Implementation projects
    Project work is the most important part of the implementation. In the ideal situation, all of the projects are directly connected to the business goals of the organization. The bigest advantages of well-defined and supported projects are:

    • A chance for the employees to use newly gained knowledge in practice
    • Achievement of measurable results, which causes immediate return from the investment
    • Convincing doubters and resistant employees to the program, through solving problems previously considered as unsolvable

  5. Creating the continuous improvement culture in the organization
    After achieving first successes, it is usually quite easy to convince people, that Lean is the right direction. You should use this time to develop internal Lean experts, who will be able not only to maintain implemented changes, but also to expand their scope in the organization and train new employees involved in continuous improvement.