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45 minutes for the same meal? Or why is it when you call some companies you get a real person in under 30
seconds and in others you're on hold for 15 minutes? Why is it that Toyota can produce a Lexus in 20 hours
of labor and yet it takes 45 hours for a cabinet maker to produce a set of kitchen cabinets? Why is it that one
bank can process a loan in 2 hours and another takes a week?
Or have you noticed that some items you buy seem to last forever and others, for about the same price, tend
to wear out in a short time?
The difference is usually in the processes the business has developed to create their products and services.
At Lean Power we have spent 25 years learning how to strip the unnecessary and cumbersome steps out of
the production process. We call this "leaning the processes," hence the name "Lean Power."
Takt time
Material movement
Parts routers
Pull systems
Supply chain refinement
Tying operations, marketing, finance, HR
Team building
Customer focusing
Setup reduction
Operations line configuration
Work station design
Cycle-time reduction
Determining need staffing levels
Inspection protocols
Fail safe design
Leadership for improvement
The DNA of quality and productivity
5-S
5-W
Just-in-time parts movement
Production smoothing
Defect reduction
Standard operations
Standard operating tools
Assembly operations
Inventory reduction
Kanban controls
Error occurrence and error detection
Error detection and error correction
Focusing on non-value-added activities
Focusing on waste reduction
Focusing on creativity
The seven wastes
Creating a bias for action
Impassioning the entire crew
The evil of WIP
Education through floor simulation
Root cause analyses
Visual control
Kaizen events
cycle times reduced by 15% to 95%
quality increased by 40%
productivity increased by 20% or more
new product to market time decreased
cost decreasing by significant amounts
capacity increases at no cost
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