Implementing Lean Manufacturing in Non-Manufacturing Environments
In a manufacturing environment moving from a "functional" (or "process") to a "cellular" manufacturing architecture can typically deliver, labour savings of 20-30% and reduce WIP and lead times typically by 50%; generating significant cash and making the typical payback period for such a project short indeed. See our article: A Lean Manufacturing Consultant's View of Cell Manufacturing.
Yet exactly the same sorts of benefits are achievable in non-manufacturing environments, such as retail or office based organisations by implementing lean manufacturing. For those wishing to make step-change improvements in cost, quality and delivery performance, implementing lean manufacturing principles offers many opportunities.
We usually advise clients to work with us as we conduct a brief diagnostic, prior to implementing lean manufacturing. See our article: Lean Manufacturing Consultancy - Diagnostic. It's important to assess the current state of the existing processes holistically and avoid any temptation to say; optimise a sub-system (by say; introducing specialist applications software) at the risk of not optimising the entire system. See our article Lean Manufacturing Consultants - a Holistic Approach.
Case Example: Implementing Lean Manufacturing in Media Co. Commercial Departments
Challenge:
- Hard working commercial departments but lots of failed promises
- Key customer said service from commercial "departments" was woeful
- Lots of changes in ownership between people as paperwork
- Extended lead-times throughout all commercial processes
- Highly unionised environment
- Temptation to think that the new computer system would be a panacea.
- New commercial manager
Departments
- Estimating (Enquiry to Quotation)
- Customer Service (Customer Order to Product Despatch)
- Production Planning & Control
- Invoicing (Despatch to Invoicing)
Activities:
- Team selected to include members representing key processes and unions
- Team building and training in principles of implementing lean manufacturing
- Team based project planning
- Monitoring of lead times for each key process
- Process mapping of all key processes.
- Identification of resources used on processes
- Identification of value-adding and non-value-adding activities
- Elimination of non-value-adding activities.
- Minimisation of the number of changes in ownership
- Configured multi-functional teams ("cells") comprised of specialists responsible for delivering each process with zero changes in ownership and minimal non-value-adding activities.
- Each team dedicated to a particular group of customers.
Benefits:
- Much improved focus on customer service
- Headcount reduction of >25%
- Process lead-times and work in progress reductions of >50%
Non-manufacturing organisations with primarily office based or retail operations that may be considering implementing lean manufacturing can reasonably expect that most lean manufacturing tools/techniques are applicable, bringing similar benefits including:
- 5S
- Statistical Process Control (SPC) & Process Capability
- De-bottlenecking
- Pull-type control systems
- Visual controls
- Self-managed teams
- Level Scheduling and Quick Changeovers
- Mixed-mode processing
- Batch splitting (Nagare)
- Etc.
More lean manufacturing tools and techniques
Executive Interims - Supply Chain Practice
In addition to implementing lean manufacturing and providing interim management services, Executive Interims - Supply Chain Practice provides clients with consultants with "Big Four" consultancy firms experience, including:
Implementing Lean Manufacturing in Your Organisation?
Unlike many of the bigger consulting firms a lean manufacturing consultant from Executive Interims will be happy to take ownership and deliver the lean manufacturing solution for you, if that's how you want to work. We're happiest when we're implementing lean manufacturing and delivering results not just advising and making recommendations.
Furthermore a lean manufacturing consultant from Executive Interims - Supply Chain Practice will always represent better value for your investment compared to a consultant from a "Big Four" firm, either by virtue of our consultants' additional expertise or their equivalent expertise but lower total cost.
Using a lean manufacturing consultant can be a particularly valuable approach when its necessary to augment an already stretched team to deal with high profile / value / risk projects.
Don't Hesitate to Get in Touch
Executive Interims - Supply Chain Practice is a specialist provider of supply chain consultancy and interim management services. If you'd like to know more about what a lean manufacturing consultant from Executive Interims can do for your business, contact us to explore the subject further. |
