KAIZEN™ in Manufacturing

From Batch and Push Production
To Unit Flow and Pull Production

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of companies want to shift to pull planning

of production time is non-value added

of productivity losses are due to the bullwhip effect

manufacturing companies spend more in IT

of sales revenue is lost due to non-quality losses

Mission

If you have the mission of:

• Shortening production Lead Times, by striving for 100% value-added activities

• Reducing stock levels while improving service level adherence

• Reaching high-quality standards with zero-defects production

Challenges

Roadblocks impeding you from fully succeeding:

Stock is pushed back into the supply chain, and no party wants to accept ownership

Forecasts are never accurate due to market volatility and uncertainty

Technical skills and knowledge are lost from the business as people come and go

It is difficult to keep up with new technologies while manufacturing processes are not yet stable

Compliance with environmental trends and regulations

Improving productivity without compromising product quality and customer satisfaction

Solutions

You need to develop:

Production Flow

• Implement one-piece flow, from raw material to finished product

• Enable mass customization by achieving the flexibility necessary for small lot production

• Eliminate non-value added activities and automate simple operations

• Implement one-piece flow, from raw material to finished product

• Enable mass customization by achieving the flexibility necessary for small lot production

• Eliminate non-value added activities and automate simple operations

Internal Logistics Flow

• Implement a seamless flow of materials, from supplier to customer

• Implement a flow of information that follows the material through all stages

• Link production with logistics to implement a pull flow system

• Implement a seamless flow of materials, from suppliers to customers

• Implement a flow of information that follows the material through all stages

• Link production with logistics to implement a pull flow system

Total Quality Management

• Achieve output quality stability through process standardization

• Acquire quick reaction capabilities to eliminate non-quality causes

• Aim for zero defects with KAIZEN™ six sigma tools

• Achieve output quality stability through process standardization

• Acquire quick reaction capabilities to eliminate non-quality causes

• Aim for zero-defect with six sigma KAIZEN™ tools

Reach best-in-class performance

Pull Flow Model in Discrete Assembly

Line Design in Automotive Assembly

Quality Improvement in Discrete Assembly

Start with a Value Stream Analysis:

During the Value Stream Analysis workshop we will create an improvement vision for your organization, business unit or department. By working alongside your team, we will understand the current state of the business processes, design the Value Stream Vision and define an implementation plan to achieve the desired results.

See VSA brochure

Ready to Start?

Find key opportunities in your manufacturing processes by conducting a value stream analysis.

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