Lean consulting and training services

Lean consulting and training services to improve production efficiency

Lean thinking makes production more efficient and improves productivity

The Lean approach aims to improve the productivity of companies, and create the best possible value for the customers. However, productivity is not improved by speeding up the work rate, but by removing various unnecessary and unproductive activities from the manufacturing process. Optimally, the benefits of a Lean model are very tangible: shorter waiting times, fewer defects, and better quality.

We train our clients’ staff in selected Lean methodologies, and create a continuous improvement model in the organization to make processes as productive as possible. With the experience of our experts, we identify and define bottlenecks and potential for improvement.

Have you encountered these challenges in developing your production?

Unclear roles and responsibilities

Carefully defined roles and responsibilities support the company’s strategy and help it to deliver on its objectives and expectations.

Projects drag on, and the results are not being put into practice

The success of a project is often measured by how well it achieves the objectives set for it. Simply keeping to the schedule is not enough; you have to keep up with the daily practices and implement them in your daily work.

Slow inventory turnover rate

The less working capital a company commits to its activities, the more efficient its operations and the lower its cost of capital are.

Too long response time for support functions

Communication between different stakeholders is essential to achieve the production objective. The conditions for successful production are improved when the basic production processes are in place.

Leaning towards a more efficient everyday production

A significant part of the principles of Lean manufacturing can be applied at almost any manufacturing company. However, in most cases, adopting a Lean approach to production requires a thorough review of the organization’s internal processes. The company’s staff are caught up in the operational process and therefore do not have time to learn new development methods. By choosing an external professional, staff learning and process improvement can be put into practice more quickly.

The change towards a Lean way of production can be a demanding but profitable path in terms of overall efficiency.

Guide - 4 steps towards Lean-production

A continuous improvement model ensures progress, and gives a competitive advantage

Two key elements of Lean thinking are the continuous refinement of processes by cutting wastes and focusing on value-adding activities, and the creation of a culture of continuous improvement. Continuous improvement means reviewing and improving the processes and performance of an organization – by all staff.

The aim of daily management is to monitor the flow and smoothness of production in line with Lean thinking. It is essential to focus on monitoring problems and challenges in production and addressing their root causes. The flow of information generated by daily management and systematic problem solving makes it possible to implement a continuous improvement model at every level of the organization.

We solve these problems, among others

Improving productivity

Productivity is improved by eliminating jointly identified unnecessary losses. The most common losses are searching, retrieving, moving and waiting. The most common bottleneck phases, on the other hand, are product changeovers, color changeovers, the prefabrication level, and day/shift changes.

Reducing manufacturing batch sizes

The longer a raw material sits in a warehouse or production process, the slower the inventory turnover rate becomes. The optimization of batch sizes aims to improve productivity and work flow, and to balance inventory and its costs. The benefits of optimizing inventory include a reduction in capital costs, storage and handling costs, wastage and the number of defective products.

Developing maintenance

Maintenance development is a form of sustainability that, if successful, enables a transition to holistic and proactive maintenance management. The key to the development work is to describe in a practical way both the current state and processes of maintenance and the future state of will and ambition. Properly selected maintenance KPIs ensure the success of maintenance, and thereby contribute to the improvement of the productivity of the whole company.

Developing safety at work

Optimally, safety at work increases productivity. By anticipating risks and hazards, accidents and injuries can be avoided. In this way, the resources needed for productive work are not spent on investigating accidents and finding those responsible. Employers are not only responsible for the safety and health of their employees, but also for assessing and preventing health and safety hazards and developing safety. Therefore, safety at work should be part of the company’s daily operations and management culture.

Best practices and modern system solutions

The manufacturing industry is a pillar of the economy, and, on the other hand, is in a transition into the digital age. Batches are getting smaller, requirements are growing, and an increasing number of services are being added to the product.

Traditionally, the competitive strengths of industry have been competence, quality, and cost-efficiency. As digitalization spreads to industry, new ways to succeed are emerging. These include speed, agility, the use of new technologies, and the ability to lead change.

We offer our customers best practices for combining digitalization and management models, software solutions that facilitate everyday life, and solutions to business challenges.

MES - production management system

The Pinja MES system facilitates the overall management of production by gathering production control and the information needed by production in one place. Read more >>

Gema – production data collection and control system

An easy and cost-effective way to develop production according to Lean principles. With Gema, you involve and motivate production operators in development and continuous improvement. Read more >>

iPES – production planning and production control system

An advanced APS system for production planning and supply chain optimization. iPES uses advanced optimization and simulation technologies to enable scenario-based what-if simulation. Read more >>

Andon – production assistance request and reporting system

A easy-to-use system for managing production assistance requests.
Andon provides a clear process for handling production disruptions and assistance requests, and helps in achieving greater security of supply. Read more >>

Novi – maintenance management system

For the modern management and development of preventive maintenance. Novi digitalizes information related to maintenance management and development, and meets the needs of daily maintenance management. Read more >>