our lean & problem solving tools

We believe that a good 5S program helps any process run better. We can take your through the S’s (Sort, Set In Order, Shine, Standardize, and Sustain) and help you implement them in a way that fits your organization. Sustaining the program is the most important step of the process, and we will help you setup a program you can sustain.

One of the keys to identifying where breakdowns are in your process is mapping. We can help you understand and utilize this tool to help identify problems and document your improved process.

When an organization uses visual management effectively, managers can quickly assess the current condition of multiple areas. This allows for easier prioritization and more time to be spent more effectively. We can help you implement a visual management system that will help your organization.

Effective use of poke-yokes can save your company time, money, and damage to your reputation due to quality escapes. We can train you on the use of poke-yokes and help you come up with an implementation plan for your product. These do not have to be costly automations, but they can save you from costly quality problems.

By mapping your value stream you can better understand your flow of material and information. We can also help you identify your non-value added steps and opportunities for waste and work to minimize them.

We utilize the PDCA cycle in almost everything we implement. We can show you how to utilize it to help you focus your efforts better and get the most out of your improvements.

If you are determining how to best layout a new area or want to re-layout an existing area, we can help you do so with a lean mindset. We will help you build in flow of material, point of use materials, standard work combination charts, ergonomics, and line balancing (to name a few).

We are fluent in the tools of six sigma as well as the DMAIC (Define, Measure, Analyze, Improve, and Control) process, however we choose not to consult on the six sigma process as it often is best used to solve different types of problems than we focus on in our consulting. We do utilize many of the same tools. To name a few: fishbone diagram, 5 why, Pareto chart, and QFD/house of quality. We prefer to “keep it simple,” and we find that most problems or processes do not need statistical analysis to be improved.

We follow a logical problem solving methodology that is more front end investigation focused than what most people use. It is data and observation driven following the Genchi Genbutsu (“go and see” mindset. You can also document the steps on one sheet of paper for easy documentation and report out to your organization (sometimes called “A3”).

While ergonomics are not necessarily a lean principle, poor ergonomics attribute to a deterioration over time of production, quality, and therefore cost. We can help you analyze the ergonomics of your work and help you make improvements that will save you time and money.