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LEAN QUEST METHODS
The Quest for realizing Lean Processes in Manufacturing, Distribution, and Supply Chains is ever pressing for many
companies in the Automotive and Electronics industries, and continues to attract attention from many others. |
| Government Market Segment - Distribution Channel |
| Service Parts Market Segment |
| Retail-Distribution Market Segment |
| Manufacturing Market Segment |
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| An Integrated System That Drives A Competitive Advantage |
| The challenges organizations face today are many. Long lead times, low service levels, network and facility constraints, low quality, high inventory levels to name a few. Add in global supply chains and a numerous acquisitions to complicate these challenges even further. The need to gain competitive advantage is a MUST. Companies are no longer just focused on working harder, but realize working smarter is key, but how? Many spent the 90's investing millions in new ERP systems that promised huge ROI's that never came, only to realize that strong, sound, and scalable processes are needed to develop and maintain a winning organization. A well-designed set of Lean Processes across your Supply Chain can yield tremendous measurable benefits. The question becomes, "not should we implement Lean, but rather HOW"? |
| The results derived from a Lean Implementation include: Increased quality, consistency, and customer responsiveness, which lead to an increase in customer satisfaction. Improved satisfaction combined with improved pricing leverage from reduced cost structures, allows for an overall increase in sales. Our Clients are able to meet the increase in sales, without adding infrastructure because of the ever-increasing capacity generated by the Lean implementation. Increased sales in an environment of reduced costs provide bottom line results of significantly increased profits. |
It is common for an organization's supply chain to see the following improvements:
Productivity increased 20% to 100%
Inventory decreased up to 50%
Capital Equipment reduced by 35%
Storage Capacity increased by 30%
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It is common for manufacturing operations to see the following improvements:
End-of-Line Defects reduced by 30%
Late Deliveries reduced more than 50%
WIP reduced more than 75%
Changeover time reduced 50% to 75% |
Clients
In a Lean implementation, successful Clients are process oriented and results based. They are committed to change and understand that the journey to Lean is an endless path of continuous improvement. Clients often face the challenges of increased competition, poor quality, demand for flexibility, or significant cost pressures. As these issues are addressed, the challenges of constrained capacity appear frequently.
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Methodology
Lean Quest's Methodology has been developed as a result of over 60 years of collective experience implementing Lean in the US. This methodology applies a three-step approach, which includes:
A needs assessment
The creation of a strategic plan
The actual implementation within the operating units
Needs assessments are conducted utilizing a combination of value stream mapping and analysis, Lean evaluation tools, and Client data. From this assessment a strategic plan is created that maps a journey to Lean that is customized to meet the unique needs appropriately for each Client. Once the implementation begins, Lean Quest closely partners with the Client utilizing a combination of proven tools and methods, coaching sessions for small teams or 1-on-1, and targeted education programs designed to address specific needs including hands-on workshops and simulations. The goal of this methodology is not only to produce results for our Clients, but also to develop a knowledge base within the Client's organization so they can become self-sufficient in the implementation of Lean. |
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