Lean System Consulting

Implementing the Lean System is a change process conducted by stages. Thus, to facilitate the process, Lean Way Consulting uses a six-stage Road Map to introduce the various elements of the Lean System.
Lean components are implemented by the Project Team, as guided by Lean Way Consultants, who use the Workshops to train multipliers, as well as everyone engaged with the implementation process.

Implementation Road Map - LEAN SYSTEM





Typical Dynamic of the Implementation Process



1- Expanding the "Assessment of Potential" to define objectives, measure targets, and establish an implementation strategy by constructing an A3 report.

2- Training: Training is scheduled during the process of constructing the A3 report, with training sessions held throughout the project. The goal is to prepare everyone involved in the project to implement Lean tools and mechanisms with the necessary effectiveness.

3- Implementation: Implementation usually takes two forms, combined in our approach:
- Kaizen Event: Kaizen Events are done by unfolding the implementation plan (A3), gathering a multidisciplinary team into a task-force to enable the implementation of improvement activities faster and more effectively.
- Work of Team Members Supported by Lean Way Consultants: Usually, Consultants develop a schedule of visits to the facility, during which he guides and supports the activities of the Implementation Plan charged to the various team members.

4- Follow-up: During “General Follow-up Meetings,” participants assess how the project has evolved and the effectiveness and rate of implementation for each activity, as well as challenges faced and results achieved, using performance indicators used for project monitoring


Internal Implementation Structure and Client Involvement

Sponsor: Involvement of the Operation/Plant's "Primary Executive" with activities developed by Implementation Team.

Implementation Team: Formation of a team charged with Project Planning (A3) and implementation, with autonomy to build the process and implement whatever changes are required (kaizen activities). The Team is made up of representatives from areas participating in the Pilot, as well as support areas and functions. Implementation Teams usually have from 10 to 15 members, depending on the size and scope of the project.

Coordinator of Implementation Team: Title of employee with training and educational background that enables him or her to learn Lean concepts and tools, knowledge and experience in operations, credibility and influence with all areas and functions involved in the Pilot.

Support Activities Provided by Lean Way Consultants

- Providing guidance regarding the implementation strategy;
- Training the project team/Developing critical mass
- Review of strategic indicators
- Providing guidance regarding the process of developing the implementation plan (A3)
- Supporting the implementation of improvement activities
- Defining roles and responsibilities
- Monitoring how implementation and results evolve