LEAN METHODOLOGY

Lean methods help organisations work more efficiently and successfully for achieving their strategic objectives related to efficiency and effectiveness targets. Lean methods are implemented for optimised management of the organisation.

Lean Practices are about efficient management

Applying Lean tools leads to faster processes, elimination of non value-adding activities, process simplification and improved focus on those activities that add value to customer experience. Customer focus and Efficiency are the primary drivers for using Lean practices.

The benefits of implementing Lean Practices are the creation of simple and faster processes based solely on the key customer requirements, smooth process flows without any delays and backlogs, reduced company costs and greater return from its products and services, happy and loyal customers.

We are offering the following Lean courses:

LEAN START: TOYOTA PRODUCTION SYSTEM

  • Module 1: Principles and concepts in Lean methods
  • Module 2: Process efficiency (FTY, RTY, OEE, WIP, DTD)
  • Module 3: Process flow (Takt time, SMED, Theory of constraints, Kanban)
  • Module 4: Process mapping and analysis, Value stream mapping 
  • Module 5: Process risk analysis (FMEA)

Audience: process management experts, operational managers, project managers

Course duration: 2 days

LEAN PRACTICES

Lean Practices are about efficient management that help organisations become successful in achieving efficiency and effectiveness targets. Lean methods are implemented for optimised management of the organisation. Lean tools support teams to execute processes faster, eliminate non-value-adding activities, and simplify processes. Improved customer focus and efficiency are the drivers for using Lean practices.

Audience: process management experts, operational managers, project managers

Course duration: 2 days

LEAN DAILY MANAGEMENT SYSTEM (LDMS)

The Lean Daily Management System (LDMS) is a set of standardized procedures that provides the structure and focus for employees with common tasks and deliverables to continuously improve their daily work. Its focus is achieving business efficiency. LDMS aims to provide the ability to manage departments and functions whereby processes are standardized, controlled and improved. The system and practices do not allow daily routine activities to slip up on daily plans and help managers gain better view of tasks, team utilisation and capacity improvement. Re-focusing managers´ time from daily firefighting to thinking and pursuing improvement initiatives is a key differentiator.

Audience: Supervisors, Managers, Executives

Course duration: 2 days

PROBLEM SOLVING WITH THE 7 QUALITY TOOLS

The Seven Quality tools are the basis to improve the process and product quality. They are used to examine the production process, identify the key issues, control fluctuations of product quality, and give solutions to avoid future defects. The seven basic tools of quality were first emphasized by Kaoru Ishikawa, a professor of engineering at Tokyo University and the father of "quality circles." You can begin your quality journey by mastering these tools, and you will master the art of problem solving methods. The training works through a real case study to bring to life the best problem solving capabilities you will get.

Audience: process management experts, operational managers, project managers

Course duration: 1 day

Audience: Professionals engaged with managing a process or a set of processes, Entrepreneurs who wish to run their businesses more efficiently and effectively, Engineers, Quality professionals, Operational managers, Project managers

ENROLMENTS

Register online by sending an email with your name and course title to This email address is being protected from spambots. You need JavaScript enabled to view it. or by calling: 0887 687 617.

Special pricing for corporate clients.

The instructor-led courses are delivered in both English and Bulgarian languages.

LEAN COUNCIL AND LEAN COUNCIL BULGARIA

Global Lean Council is a community of professionals who share a passion for organisational improvement. We are committed to providing opportunities for growing professional skills, and creating awareness and competence to drive process improvements in organisations.

We support our members by:

- sharing clear standards and guidance for implementing continuous improvement practices based on quality improvement methods (Lean and Six Sigma toolbox)

- developing skills by providing training and development opportunities for professionals

- supporting organisations in their journey to become best in class companies, and create competitive advantages based on quality improvement practices We work with individual professionals and organisations around the globe.

Apply for FREE professional membership by sending a mail to This email address is being protected from spambots. You need JavaScript enabled to view it.. Professional membership ensures you become part of a lean community focused on continued skills development. You can use the related membership discounts on training and certification programs.

CONSULTING

Working in an efficient and smart way promotes better quality and improved customer experience.

What we can do for your organisation:

  • Diagnose your current processes to assess operational effectiveness
  • Identify areas for achieving business improvements
  • Improve your daily operations
  • Support you to drive key process changes
  • Implement process improvements
  • Raise quality levels across the company

What is Lean methodology?

Lean methodology originated in manufacturing and this is where the concept of lean manufacturing came from.

Lean methodology refers to using Lean both in manufacturing and service industries

There are many reasons why you need Lean methodology:

  • Improve the overall quality of your processes and services – you can deliver better, faster and using less resources because lean methodology will optimise your operations
  • Achieve standardisation of processes – having standardised operations means predictability. The customer will know when to expect your products and you will always be able to meet his needs. Lean methodology helps do that.
  • Lean methodology takes the customer view when the process is designed – what are the key customer requirements that you need to meet
  • Lean methodology helps you remove the waste for your processes – waste that does not add value to your customers for an improved customer experience

Some of the typical problems that Lean methodology can solve are related to improving the work practices – eliminating errors in databases, mistakes in one’s area of work, wrong deliveries, bad planning that all lead to generating losses. The complicated procedures and processes mean longer delivery times, the complex and unclear working procedures and confusing roles and responsibilities impact the customer in a negative way. Achieving fast, smooth and uninterrupted processes are the main objectives of lean methodology.

Implementing Lean methodology

Lean metodology

When we talk about implementing Lean methodology, we have the following sequence in mind:

First of all, start from the customer and define what the customer wants and what the customer defines as value adding, so that you know where to focus. This is primary step in implementing lean methodology.

Once you know that, you need to map out your process so that you create a value stream that captures and differentiates value adding from non-value adding activities.

Thirdly, with Lean methodology try to decrease or fully eliminate those non-value adding steps that stumble the process.

Then, as part of lean methodology application, you need to ensure the pull-principle is in place – that is a step in the process becomes needed only when the previous one is complete. This means that you will not be able to overproduce or deliver at a time when your product is not needed as this in turn can generate inventory, and therefore waste.

Once you remove the non-value adding steps, lean methodology requests that you test the process for completeness and its ability to deliver what it is designed to deliver. This is a key step in implementing lean methodology.
Keep moving and continuously improving your process until you are confident that a state of near perfection is reached, in line with lean methodology principles.

Investing in measurement to how the process is performing is a good way to keep it on track and notice any signals of deviations on time to able to proactively fix before they become big issues or before your process gets off-track. Lean methodology promotes the use of measurements to track and report performance changes.

If not sustained and controlled, processes tend to go back to their original old state.

Lean Methodology as Management Philosophy

  • Lean methodology and stable processes: stable processes mean low variations, solid product design, less waste (Jidoka, Poka-Yoke). With lean methodology the company works towards establishing standards and documenting these in Standard Operating Procedures (SOP). Having the inbuilt quality into the design of a product or service means that we have considered the customer view and that customers will be happy when they receive it.
  • Lean methodology and quantity control: Lean methodology uses a number of tools that ensure processes are in control and run as per the customer requirements (Just in Time, Pull manufacturing and Kanban Systems, Takt, Heijunka). In a culture that has lean methodology at its core, leaders support simplified and visual processes as opposed to complex processes. Pull systems are favoured as opposed to Push systems.
    Lean methodology and productivity improvements: the use of lean tools ensure that we work towards improving operational performance that lead to productivity improvements. Such lean methodology tools are 5S, Autonomous maintenance, and others.
  • Lean methodology and continuous improvement: the Lean approach has Continuous Improvement at its heart. The use of tools such as Kaizen and Visual management practices enhance productivity of the whole system of processes. Visual management is favoured in the use of lean methodology, as visualisation and performance make trends and relationships more visible than simple status reports.
  • Lean methodology supports the learning organisation. When it comes to people, empowering employees and using people potential is a number one reason why Lean methodology is favoured by employees and managers alike. Taking ownership of issues and resolutions allow staff to feel part of the company and also take personal responsibility for the work done. This results in better employee engagement and commitment. Going beyond the use of lean methodology, a lean culture requires a shift in how people think.

We use Lean methodology to support industries

SERVICES SECTOR: Providing best-in-class service is a challenge to all companies around the globe. We have the experience and the expertise to support you with service quality improvements as part of applying lean methodology tools. We are trusted experts in raising the levels of service quality to ensure the best customer experience through:

SERVICE QUALITY ASSESSMENTS: We use methods for Service Quality Assessment to benchmark the current status for your services and identify the gaps that you need to close to become a world class service provider.

SERVICE QUALITY IMPROVEMENTS: Focus the improvements that are needed in order to take your organisation to the next level. Identifying and working on the right areas impacts your customers and guarantees more business. We use lean methodology in combination with six sigma to support the improvements.

MANUFACTURING SECTOR: Manufacturing is traditionally an area for implementing quality improvements through Lean methodology and Six Sigma methods. Improving the production process and productivity is done through:

  • Review of the existing workflow
  • Identifying inefficiencies and updating process and technology
  • Commit to scheduled maintenance (as part of lean methodology application)
  • Train employees on lean methodology and six sigma methods
  • Organise the workplace and maintain optimal inventory (use of lean methodology best practices)

LEAN PRACTICES ARE ABOUT EFFICIENT MANAGEMENT
LEAN START: TOYOTA PRODUCTION SYSTEM
LEAN PRACTICES
LEAN DAILY MANAGEMENT SYSTEM (LDMS)
PROBLEM SOLVING WITH THE 7 QUALITY TOOLS
ENROLMENTS
LEAN COUNCIL AND LEAN COUNCIL BULGARIA
CONSULTING
WHAT IS LEAN METHODOLOGY?
IMPLEMENTING LEAN METHODOLOGY