Lean Transformation Consulting by xru14808

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									  Lean Transformation Consulting




www.procexcellenz.com
Our Value Proposition

                              Our Lean Recipe that
                               is derived from best
                               practices of globally
                               admired companies



           Overseeing
        Transformational                                Flexible composition
          Lean Culture                                  in our Lean packages
         Change into the                                 to suit Mid Market and
          fabric of your                                   Small Businesses
           organization
                                  Our Value
                                 Proposition




                     Focus on
                Competency and
                                               Superior Value over
                   Leadership
                                               the term at the right
               development in your
                                                  program cost
               Team to become self-
                    dependent




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Our Offerings




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Our Firm‘s Team capability

    Lead Consultant has a 13+ year career at Caterpillar Inc.’s Asia office as
        Certified 6 Sigma Master Black (Black Belt)
        Qualified Lean Black Belt & Champion
        Strategic Sourcing and Cost Management Consultant

    Led deployment to and consulted for 4+ Mid-sized businesses in India alongside 6
     Sigma deployment programs, over the last 2 / 3 years.

    Industries served are Manufacturing, Automotive, Logistics & Transportation,
     Healthcare, Financial Services and Hospitality

    Industry Partners for special assignments / training sessions on call, to deliver
     superior value and optimize client costs.




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What is Lean Transformation ?

   Built around Toyota Production System (TPS)
   Focused on systematic waste elimination in the Order Fulfillment Chain to:
     Improve Safety
     Improve Quality
       Improve Capacity
       Improve Availability
       Reduce Cost
     Systemic business transformation of Manufacturing and Transactional
      environments by
       Embedding TPS principles and
       Bringing about Cultural Change
     Uses 6 Sigma disciplines and Lean Tools to deploy and improve
     Drives towards best-in-class standards of Order Fulfillment performance
     One Common Deployment approach for our Clients




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Lean Transformation = War on Waste




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Lean Transformation across the Value Chain

Lean extends across the entire Order Fulfillment Value Chain


  Supplier             Factory                     Dealer                   Customer




        Supply Chain     Manufacturing Operations           Distribution Channels




 Lean Transformation drives out waste, continually improve processes
 in each of these segments, and achieve Safety, Quality, Capacity,
 Availability and Cost targets.


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   Typical sub-processes transformed with LEAN
                                             Production Planning
Supplier Capacity / Supply Chain Planning                                                    Production Planning




                                                                               Orders Mgmt




    In-bound Shipping
                                            Manufacturing Scheduling
                                                                                                 Outbound Shipping




    RG Inventory Mgmt                                                                           FG Inventory Mgmt

                                                                Capacity Planning
                                                          Process Planning
                                                     Quality Planning




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30,000 feet view of Lean Deployment
   Company Goals


          Product or Process VS 1
           Product or Process VS 2
             Product or Process VS n



                                    Current State VS1                                       Future State VS1


                                                                 Visionary Goals




                                                                                   Kaizen / RI
                                                                    Execution      Workshops
                                                                                     6 Sigma
                                                                                     Projects


            Lean Principles and Culture built into the Company

              Lean Leadership Competency Development


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How we help you with your Lean Transformation
                         Pre-assess your Company for readiness and gaps (Processes, Principles & Culture)
                         Establish Company-level Metrics, Baseline performance and Future targets
 Phase 1 (4 months)




                         Value Stream (VS) planning
                              Identify various VSs within the Company
                              Establish VS-level Metrics, Baseline performance and Future targets
                              Compare and prioritize them based on gaps against targets, opportunities, impact needed and
                               resources available
                         Administer Core Lean / VST / Kaizen / RIW Training (Lean competency building)
                              Deployment Champion & Executive Leaders
                              Lean Black Belts / Green Belts
                              Lean Awareness (Yellow Belts / Rest of the Employees)

                         Charter and launch 6 Sigma parent-projects for each VS (Map Current & Future states)
                      
 Phase 2 (8 months)




                          Identify and spin-off Kaizen or RIW or 6 Sigma child-projects from each VS
                         Project Execution, Coaching and Program Governance
                              Establish a Portfolio of multiple Lean (parent + children) Projects
                              Establish Dashboards to report Program Health (Executive-level, VS-level, Project-level)
                              Establish a Management Review system for the Lean Projects Portfolio
                         Perform a Year-end Company-wide reassessment (Processes, Principles & Culture)
                         Transition the Lean Program to the Company Deployment Champion
                         Hand-hold and provide ongoing Coaching / Training support as needed

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  Lean Transformation Training




www.procexcellenz.com
Training Programs - Index



     Program                            Target          No. of days
                                        Candidates
     Deployment + Executive Training    DC + Leaders    2 days
     Lean Training                      Black Belts     10 days
     Lean Training                      Green Belts     4 days max
     Lean Training                      Yellow Belts    1 day




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Training Delivery Suite of Options
  Delivery Options            Client       Instructor     E-learning    Printed        Exercises   Coaching
                              Location     Led            (Self         Books /        + Real      Support
                                           (Facilitated   Taught –      CDs (Self      Examples
                                           – 10+ pax)     1+ pax)       Taught)
  Deployment Champion

  Executive Leaders

  Black Belt

  Green Belt

  Yellow Belt


                        Primary Option (10+ Belts preferred per Session of Training)
                        Secondary / Low Cost Options (1+ Belts)
                        Tertiary / Mandatory provisions




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  Deployment Champion / Leadership Training
Road Map preparation
• Develop a Master Plan for Lean Transformation                                    With our Comprehensive
• Assess current state and prepare for Cultural Change                             Training Program your
• Identify and train Lean Black Belts and Green Belts
                                                                                   Lean Champion will be
     Value Stream identification                                                   able to :
     • Identify Product and Process Value Streams in the
      Company                                                                         Assume the Champion roles
     • Develop Metrics and prioritize Value Streams based on
      Gaps                                                                         and responsibilities
                                                                                       Manage the VST and RIW
                                                                                   project prioritization and
           VST Planning
                                                                                   selection process
           • Develop Current State and Future State VSMs
           • Develop an MGPP for phased transformation                                 Employ new management
                                                                                   skills to lead cultural change in
                                                                                   your business environment
                Kaizen Event and 6 Sigma Project generation
                                                                                       Feel empowered to make
                • Spin-off Kaizen Event or RIW projects and 6 Sigma
                 projects                                                          changes in project focus
                • Develop and manage a portfolio of Lean projects                      Remove roadblocks
                • Implement Cultural Change Plans                                  associated with VST projects
                                                                                       Influence the leaders of
                      Benefits Validation and Gap Reassessment                     support functions needed for
                      • Validate Project benefits with Finance Team                project completion
                      • Assess for VS Metric Gaps and launch additional Projects




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Lean Black Belt Training

                             VS or RIW             VS or RIW
                                                                            Holding the
        Ground Work          Problem                Problem
                           Identification          Resolution                 Gains




      Classroom       Lean Project Phase     Training Agenda
      Training
      Week 1          - Ground Work          • Introduction to Lean and relevant Culture
                      - VS / RIW Problem     • Current State VSM
                      Identification         • Safety, Ergonomics, Quality, OEE, TPM, 5S
                                             • Waste Identification
                                             • Process Improvement Dialogues
                                             • Drive Standard Work
      Week 2          - VS / RIW Problem     • Future State VSM
                      Resolution             • Error Proofing, QCO
                      - Holding the Gains    • Concepts - Stabilize, Flow, Pull, Level
                                             • Develop MGPP
                                             • Kaizen Events / RIW Plans
                                             • Develop People / Leaders


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Lean Green Belt Training


                                        VS or RIW                 VS or RIW
                                                                                              Holding the
             Ground Work                 Problem                   Problem
                                      Identification              Resolution                    Gains




 Classroom Training        Lean Project Phase              Training Agenda


 Day 1 & 2                 - Ground Work                   • Introduction to Lean and relevant Culture
                           - VS / RIW Problem              • Current State VSM
                           Identification                  • Safety, Ergonomics, Quality, OEE, TPM, 5S
                                                           • Waste Identification
                                                           • Process Improvement Dialogues
                                                           • Drive Standard Work

 Day 3 & 4                 - VS / RIW Problem Resolution   • Future State VSM
                           - Holding the Gains             • Error Proofing, QCO
                                                           • Concepts - Stabilize, Flow, Pull, Level
                                                           • Develop MGPP
                                                           • Kaizen Events / RIW Plans
                                                           • Develop People / Leaders




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Lean Yellow Belt Training




     Classroom   Lean             Training Agenda
     Training    Methodology
     Day 1       Overviews        • Introduction to Lean and Sub-systems
                                  • 7 types of Wastes
                                  • 15 principles of Lean Transformation
                                  • Concepts – Stabilize, Flow, Pull, Level
                                  • VSTs and RIWs
                                  • Roles and Responsibilities




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E-Mail: info@procexcellenz.com, procexcel@gmail.com
Phone : +91-44-27665665 / Mobile : +91-9677754111

Procexcellenz is a premier provider of multi-channel Consulting and
Training Solutions for seekers of 6 Sigma, Lean, Stategic
Sourcing, Cost Management and Strategy Planning services.




www.procexcellenz.com
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