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Lean 4.0
Today's business environment is characterized by unique challenges and complexities in manufacturing. Successfully implementing strategies such as Lean 4.0 has become a key challenge for companies. If not properly executed, the results may not reflect the effort and resources invested, making it difficult to sustain operational gains over the long term.
The adoption of a continuous improvement methodology is becoming increasingly essential to remain competitive in this dynamic market. This methodology makes it possible to accelerate product innovation, improve quality, reduce operating costs, eliminate waste and, in general, enhance the value proposition offered to customers. The ability to constantly adapt and evolve has become crucial to respond to changing market demands and to ensure long-term sustainability in an ever-changing business environment.
At London Consulting Group, we
develop and apply the Lean 4.0 methodology
to optimize your production processes
Ensure your company's growth through the correct implementation of customized agile methodologies such as Lean 4.0. Capitalize on digital data mapping to accelerate the pace of the improvements which yield tangible results in production efficiency and improve the effectiveness of your working capital, enhancing operational excellence.
SOLUTIONS
How we achieve continuous improvement in organizations
We focus on the uniqueness of each production process through a thorough analysis in order to successfully implement the Lean methodology. Our Lean 4.0 methodology is developed with a focus on agile leadership, active collaboration, and proactive problem-solving, establishing a culture of continuous improvement in an organization. This approach positively impacts the company’s overall efficiency by implementing a culture rooted in continuous improvement.
METHODOLOGY
Our process towards Lean 4.0
Operational Excellence
Deep-dive Analysis
We analyze all the company’s departments and processes, taking into account both internal activities and the final customers’ experience. This assessment allows us to identify the current performance at each stage of the process and critical points that need to be improved.
How we do it
• Defining key objectives and goals: Establishing specific and attainable goals that the company seeks to achieve and that are aligned with its long-term vision. These objectives are vital, as they enable the company to focus its efforts and measure success.
• Analyzing the current organizational culture: Detailed assessment of the values, beliefs, behaviors, and practices that shape the company's work environment. Understanding the organizational culture is crucial to implementing successful changes and aligning strategies with the existing culture.
• Evaluating the performance of the current processes: Comprehensive review of the internal processes to identify their level of efficiency, identify bottlenecks or areas for improvement, and determine whether they’re aligned with the organizational objectives.
• Defining key performance indicators (KPIs): Identifying and establishing specific metrics to measure the progress made towards the defined objectives. These KPIs are instrumental in assessing performance and adjusting strategies when necessary.
• Evaluating the company’s tools and technologies: Analyzing the tools, systems, and technologies that are used in the business processes to determine their effectiveness, efficiency, and alignment with strategic goals.
• Defining the key project areas: Identifying priority areas that require immediate attention or where the changes or improvements will be focused.
• Evaluating customer satisfaction and expectations: Gathering data and analyzing the customers’ perceptions of the company’s products and services, and their overall experience. This is essential for adjusting strategies and improving customer relationships.
Project
We are focused on aligning the institution’s organizational culture with the continuous improvement mindset to achieve transformation and operational excellence.
Innovation and Digitalization
• Defining, designing, and implementing sources of data: Identifying, designing, and establishing various data sources that will be used to collect relevant information. This involves determining what data is needed, how it will be collected and stored, and how it will be accessed.
• Flow design and implementation: Creating a smooth and efficient process for moving the data through the different stages, from initial collection to storage, processing, and analysis. This ensures that the data is effectively transferred throughout the system.
• Creating a data lake: Establishing an infrastructure or environment that is suitable for storing large volumes of data in a secure and accessible manner. This "data lake" allows data to be centralized and organized, facilitating its analysis and use.
• Modeling indicators for decision-making: Developing specific models and metrics that will be used to evaluate performance and provide key information for the decision-making process. These indicators are based on the collected and processed data.
• Determining automated decisions: Implementing automated systems or processes based on predefined rules or algorithms that use data and indicators to make operational decisions. This enables quick and efficient responses to specific situations without direct human intervention.
Planning and Programming
• Designing and implementing the S&OP (Sales and Operations Planning) model: Developing and implementing a comprehensive process that integrates sales and operations planning to better coordinate demand and production capacity. This model ensures closer alignment between the sales, marketing, finance, and operations departments.
• Planning and scheduling model: Creating a detailed model for scheduling activities within the company, enabling better coordination of resources, time, and activities. This may include optimizing the production schedules, the allocation of resources, and inventory management, among other aspects.
• Designing the capacity plan tool: Developing a specific tool for planning the production capacity, taking into account available resources, projected demand, and other relevant factors. This tool helps optimize the company's operating capacity.
• Implementing the MRP (Material Requirements Planning) / MPS (Master Production Schedule) / FCE (Finite Capacity Scheduling) models: Implementing specific computer systems or models for material requirements planning, master production scheduling, and finite capacity scheduling. These models help to efficiently manage the company’s materials, production, and available resources.
Line Engineering
• Line balancing and work design: Process aimed at efficiently distributing tasks and activities among the workers and workstations, with the objective of minimizing bottlenecks, maximizing productivity, and reducing waiting times.
• Time and task studies: Detailed analysis and accurate measurement of the time required to perform each task or activity within a process. This involves carefully studying the work methods, the time required to complete a task and the employees’ performance.
• Constraints analysis: Identifying and evaluating the limiting factors or restrictions within the company’s production processes or operations. These may be limited resources, insufficient capacities, or any other factor that hinders efficiency.
• Layout redesign and defining the CAPEX: Reorganizing the physical design and distribution of the elements within a plant or workspace to improve efficiency and optimize workflow. Defining the CAPEX (capital expenditure) refers to identifying and budgeting investments in long-term assets, such as machinery, equipment, or infrastructure, that are needed to implement design changes and improve efficiency.
Production
• Designing and implementing high-performance teams: Creating and implementing teams that focus on maximizing their performance and productivity. This involves identifying complementary skills, managing conflicts, and ensuring effective collaboration and motivation to achieve optimal results.
• Configuring new operational templates: Developing and establishing new formats or operational structures that are better adapted to the company's processes in order to improve efficiency and the quality of the work.
• Floor control model: Implementing a real-time supervision and management system in the production area or on the work floor, enabling the operations to be continuously monitored and the ability to intervene quickly if problems arise.
• Implementing automated indicators and dashboards: Developing and implementing key metrics to measure performance and productivity that are then presented through automated dashboards that provide real-time information on the status of the processes.
• Implementing an Innovation Hub: Creating a space or platform aimed at fostering creativity and innovation within the company. This "Hub" facilitates the generation of new ideas, experimentation, and the development of innovative projects.
• Coaching and development model: Establishing a structured coaching and development program to improve the personnel’s skills and knowledge, promoting their professional and personal growth within the organization.
Maintenance (Asset Management)
• Preventive and predictive maintenance model: Developing and implementing a structured approach to maintaining the equipment and machinery in optimal conditions. Preventive maintenance focuses on scheduled inspections, cleaning, and replacement of parts to prevent failures. Predictive maintenance uses technology and data to predict potential failures so that actions can be taken before they occur.
• Implementing control software: Adopting and integrating systems and specific digital tools for maintenance control and management. This software can help with maintenance scheduling, task tracking, spare parts inventory management, and equipment status reports.
• Strengthening the maintenance routines: Strengthening and improving existing practices in the maintenance process. This may include reviewing and optimizing procedures, strengthening the training provided to the personnel involved, and implementing stricter standards to ensure that the maintenance work is carried out efficiently and consistently.
BENEFITS
Operate with efficient and cost-effective processes
We are committed to ensuring continuous improvement in your company, accelerating product and service innovation with high-quality standards while optimizing costs through the efficient use of resources and working capital. By achieving operational excellence, you will be able to increase your profits, improve your sales, and reduce operating costs and expenses, allowing you to compete successfully in today's marketplace.
What makes us different
• Implementing a Lean 4.0 methodology that is adapted to the company.
• Achieving operational excellence through streamlined processes and systematic execution.
• Reducing production costs and expenses by improving the processes across the operations.
• Digitizing the operational processes to optimize control on the work floor.
• Data mapping and modeling for efficient management processes.
• Transforming the organizational culture towards one of continuous improvement.
TRENDS
State-of-the-Art Operational Optimization
By early 2020, approximately 25% of leading manufacturing companies had taken a bold leap by adopting solutions based on process optimization and artificial intelligence (AI). By 2021, this percentage skyrocketed to 76%, demonstrating the real impact AI is having within production processes. Lean 4.0, enables faster and more accurate decision-making, optimizes processes, and increases operational efficiency. During the same period, only about 10% of manufacturing companies had implemented the Industrial Internet of Things (IIoT), a technology that promises to revolutionize connectivity and data collection in manufacturing. By 2025, IoT adoption is projected to rise to 50%, with a substantial market share valued at over $200 billion.
Top 10 Manufacturing Trends, Exploding Topics