Lean Manufacturing Consulting

Lean Manufacturing is “a systematic approach to identifying and eliminating waste (non-value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection.” The focus is on improving lead times, quality and operating costs and requires employee involvement to be successful.

We take the proven concepts in lean manufacturing and apply them to the unique situation, needs and environment of the company.  However, Lean is not a one size fits all approach and not every lean tool is applicable for every manufacturer.

Business Challenges that may be Improved using Lean Manufacturing Tools

  • Too busy fighting daily problems to make improvements
  • Staff is not able to deliver on the increased orders
  • Extended delivery times are chasing customers away
  • There has to be a better way but not sure how or where to start
  • The cost to produce is rising faster than the price a company is able to sell to customers
  • Lean efforts in the past did not seem to stick
  • Struggling to move beyond the training and into implementation

Catalyst Connection’s Lean Manufacturing Difference

We believe that successful lean deployment is 20% dependent on tool expertise and 80% dependent upon the leadership and culture in which they are utilized. We want to partner with companies that are looking to transform their business through a comprehensive continuous improvement approach. Our Lean Manufacturing Consulting is based on the Plan-Do-Check-Act approach and allows us to create a deployment aimed at both short and long-term success for the client.

Tools for Success

  • 5S (Sort, Set in Order, Shine, Standardize, Sustain) – A simple, yet highly effective, low-cost way to improve workplace organization and operational efficiency
  • Cellular Flow – Optimally produce a variety of products with little waste through this technique
  • Improvement KATA/Coaching KATA – Universal means of developing solutions in any situation is the best way to prepare for the challenges ahead learn more
  • Kaizen – Concentrated approach to process improvement, focusing on a slow and constant continuous improvement
  • Lean Assessment – Evaluate the current situation focusing on: Improvement Readiness, Culture, Leadership, Key Performance Indicators and Return on Investment
  • Lean Certification – A full program that provides all of the fundamentals needed for a champion of lean activities
  • Lean Office – Applying lean and organizational tools to the administrative side of the business
  • Practical Problem Solving – A systematic approach to empowering every employee to solve problems quickly and effectively using an A3 methodology
  • Setup Reduction – Time elapsed at a work center from when the last good part of the current run is completed until the work center starts running the first good part of the next run.
  • Standardized Work – Eliminate variations by defining each step in the and perform them uniformly every time.
  • Value Stream Mapping – Highlight inefficiencies and waste, and illustrates the best approach to resolve them.
  • Visual Management – Incorporates a range of tools for accurate, efficient communication, designed to turn conventional manufacturing settings into “visual factories.”