Lean and Green™ Manufacturer of Collectibles and High Volume Products
We facilitated a session with our client’s Team to ensure a shared high level of understanding of Value Mapping techniques that would be required for effective Future State Implementation. The Current State was completed and analyzed. A Future State (FS) and a detailed Future State Implementation Plan was developed.
THE ENVIRONMENT PRIOR TO OUR INVOLVEMENT
This manufacturer was familiar with Lean and in the past had demonstrated good progress with continuous improvements. Some of the green aspects were new but of great interest in terms of being able to show measurable reductions in Green House Gases (GHG) and to improve the air quality for employees.
Over time, with attrition and other factors, there had been slippage away from proper Lean transformation and ‘systems ‘thinking to making ‘point improvements’. Management was keen to refresh employee’s Lean focus and to see what results could be obtained by applying both Lean and Green to one of their value streams.
OUR CHALLENGE:
To apply Lean & Green™thinking and tools to a Value Stream that had the advantage from Lean application in the past but needed refocus and the enthusiastic engagement of everyone involved.
IMPLEMENTATION
We facilitated a session with our client’s Team to ensure a shared high level of understanding of Value Mapping techniques that would be required for effective Future State Implementation. The Current State was completed and analyzed. A Future State (FS) and a detailed Future State Implementation Plan was developed.
In the proposed Value Stream, the FS Implementation Plan created by the Lean Advisors consultants and Client Team, identified five major opportunities for improving processes and an additional three areas where energy consumption could be reduced within the next few months.
Overall Outcome:
Savings (from this one Value Stream):
- $1M+ savings from a reduction of work in progress
- 5-8% reduction in energy cost
- A release of staff for redeployment
- A 9% in carbon footprint
- Identified areas for toxin reduction