Implementation of Operational Excellence through Lean Thinking

Lean thinking – Manufacturing, Services, Retail, Construction, Information Technology

As part of implementation of operational excellence, Seven Steps uses Lean Thinking.  Lean has origin from Toyota, Japan with original name of TPS – Also called Toyota Production System.

Even though the roots of Lean is from manufacturing background and particularly automobile manufacturing, it is successfully adopted as key methodology beyond automobiles and works beyond Toyota and Japan.

Lean in Services, Lean Hospitals, Lean Retail, Lean Construction, Lean IT, Lean Government reflect wide application of Lean thinking across multiple sectors. Those who have deployed Operational Excellence through Lean Thinking have realized Productivity improvement, Quality improvement, Cost reduction, Improved Delivery through reduced lead times, improved morale of people and improved work place organisation & safety.

Team Seven Steps have wide implementation experience in deploying Lean thinking across industry sectors.

If you are looking for improving your organisation performance to higher levels, it is right time to consider operational excellence deployment.  Seven Steps will be glad to provide you support in steering this journey with more ease and effectiveness.

Partial list of industries and sectors where our services are valued

Hospitality
Insurance
Telecom
Stamping
Airports
Transportation
Airlines
Schools
Colleges
Commercial printing
Retails outlets
Warehouses
Logistics
Facilities
Aerospace
Apparels
Automotive & Ancillaries
Bio-Technology
Construction
Engineering Plastics
Fabrication
Farming
Food processing
Forging
General Engineering
Infrastructure
Kitchens
Machine building
Machining Technologies
Mining
Moulding Components
Non-conventional energy
Pharmaceuticals
Process Industries
Railway products

Examples of results achieved by our customers

  • Reduction of order backlog from 1500 orders to ZERO in six months using lean approach
  • Realization of Business goals using Hoshin- Kanri Process
  • Reduction of manufacturing Lead-time by 50 %
  • Sales improvement by 200 %
  • Improvement of Customer Satisfaction Score by 35 %
  • Improvement of Warehouse Efficiency by 100 % using lean methods
  • Reduction of tool changeover time by 50 % using SMED concept
  • Breakdown reduction by 90 % using TPM approach
  • More than 5000 Kaizens most of them from front line employees
  • Productivity improvement 100 %
  • Inventory Reduction by 50 % using lean and TOC methods
  • 4 National level recognitions
  • Customer appreciation – Visual Factory

To know more about our services and solutions

Benefits of Lean thinking in manufacturing operations.

  • Improving Ontime in Full Delivery performance (OTIF)
  • Reduction of Cost of Poor Quality (COPQ)
  • Improved morale and safety at work place
  • Reduction of backlog orders.
  • Reduction in cost of manufacturing through improved efficiency
  • Increased capacity

Some of the tools associated with Lean thinking which are used in meeting above objectives are:

Applied 5S, Value Stream Mapping and design, Kanban, Pull system, Load levelling, Supermarkets, Point of use storage, Just in time, SMED or QCO, Bottleneck management

Lean solutions will help overcoming the following challenges faced by manufacturing industry.
  • Long lead-time from Customer order to Delivery High Inventory.
  • Fire-fighting in Daily Management
  • Unskilled workforce, low flexibility.
  • Un-predictable customer demands
  • High absenteeism affecting delivery.
  • Low first time yield, high quality rejections
  • Low employee morale, No team work
  • High attrition
  • High cost of Manufacturing and Delivery
  • Un-organized, Un-Safe, Stressful workplace
  • Long product development lead-times

Benefits of Lean thinking in services

  • Improving Ontime fulfilment.
  • Improve responsiveness.
  • Reduction of Cost of Poor Quality (COPQ)
  • Improved morale and safety at work place
  • Reduction of backlog orders.
  • Improved work efficiency.
  • Increased capacity

Some of the tools associated with Lean thinking which are used in meeting above objectives are:

  • Applied 5S
  • Value Stream Mapping and design
  • Kanban,
  • Pull system,
  • Load levelling
  • Supermarkets
  • Point of use storage
  • Just in time
  • SMED or QCO
  • Bottleneck management

For hand-on – onsite support for implementation of Operational Excellence or focused implementation of any of the tools

Benefits of Lean thinking in construction

  • Improving Ontime performance
  • Improve quality of construction
  • Reduction in lead time
  • Improve responsiveness.
  • Improve first time right – Reduction of Cost of Poor Quality (COPQ)
  • Improved morale and safety at work place
  • Improved work efficiency.
  • Increased capacity
  • Elimination of penalty and legal issues.

Some of the tools associated with Lean thinking which are used in meeting above objectives are:

  • Applied 5S
  • Value Stream Mapping and design
  • Kanban
  • Pull system
  • Load levelling
  • Supermarkets
  • Point of use storage
  • Just in time
  • SMED or QCO
  • Bottleneck management

Benefits of Lean thinking in retail

  • Improving Ontime performance
  • Improved responsiveness
  • Reduction of serious customer complaints that affect the business.
  • Reduction in lead time
  • Improve first time right – Reduction of Cost of Poor Quality (COPQ)
  • Improved morale and safety at work place
  • Improved work efficiency.
  • Increased capacity
  • Optimisation of inventory.
  • Reduced cost of operations due to high value addition by every employee

Some of the tools associated with Lean thinking which are used in meeting above objectives are:

  • Applied 5S
  • Value Stream Mapping and design
  • Kanban
  • Pull system
  • Load levelling
  • Supermarkets
  • Point of use storage
  • Just in time
  • SMED or QCO
  • Bottleneck management

Benefits of Lean thinking in Hospitals and Health Care Services

Some of the key benefits of applying Lean in Hospitals and Health care services are  Effective service delivery, improved patient experience and reduced costs both for hospitals and for patients.

These benefits are achieved through:

  •  Effective and organized workplace through 5S  and Visual Management.
  • Improved responsiveness across the functions
  • Improved team work among functions
  • Standardized work which help in faster services
  • Improved customer delight with humane approach
  • Effective inventory management which helps in improved availability and elimination of stock-outs and excess stocks.
  • Effective facilities and equipment management through application of Total Productive maitenance.
  • Continuous improvement and people invovlement through structured Kaizen Culture

Seven Steps team are a set of highly passionate professions and always willing to support for Human cause and improved living standards for people around the World.  We will be glad to associate with aspiring Hospitals and Health care service providers who really wanted their organisations to be truly World Class.

For further support, Get in touch with us.

For hand-on – onsite support for implementation of Operational Excellence or focused implementation of any of the tools