2.2 Lean, Continuous Improvement, and Operational Excellence

Customized Lean Deployment

Overview:

Our Customized Lean Deployment service is designed to support organizations in adopting Lean principles tailored to their specific goals and operational needs. We work closely with your team to develop and implement a comprehensive action plan that focuses on eliminating waste, improving efficiency, and creating a culture of continuous improvement. With a flexible approach, we adapt Lean methodologies to fit your organization's unique processes and environment. 

Key Benefits: 

• Waste Reduction: Identify and eliminate non-value-added activities, leading to more efficient processes and improved productivity.
  
  
• Improved Team Collaboration: Foster teamwork and accountability, enhancing communication and collaboration across all levels of the organization.
  
  
• Increased Flexibility: Implement adaptable processes that can respond quickly to changes in customer demand and market dynamics.
  
  
• Enhanced Problem-Solving Skills: Equip your team with Lean tools and techniques to effectively address operational challenges and drive innovation.
  
  
• Sustainable Growth: Build a culture of continuous improvement that supports long-term success and operational resilience.

Send a Request

Hoshin Kanri (Lean Policy Deployment)

Overview:

Our Hoshin Kanri (Lean Policy Deployment) service helps develop a structured methodology for aligning strategic goals throughout the organization. Building on Peter Drucker’s “Management by Objectives” (MBO), this service incorporates Total Quality Management (TQM) tools and introduces Japanese adaptations such as vertical and horizontal catchball, fostering greater collaboration across all levels of the organization. The approach ensures that key objectives are communicated effectively, and strategies are aligned from leadership to front-line teams. We also assist with the formulation of A3s for catchball execution and x-matrices to track progress and performance against strategic goals. 

Key Benefits: 

• Organizational Alignment: Achieve top-to-bottom and cross-functional alignment of strategic objectives through systematic deployment.
  
  
• Improved Communication: Leverage the catchball method to enhance both vertical and horizontal communication within your organization.
  
  
• Strategic Focus: Develop a clear, focused plan for achieving organizational goals with a structured framework.
  
  
• Enhanced Collaboration: Foster teamwork across all departments, ensuring buy-in and accountability at every level.
  
• Performance Tracking: Utilize A3s and x-matrices to monitor progress and ensure continuous alignment with strategic objectives.

Send a Request

Value Stream Mapping

Overview:

Our Value Stream Mapping service provides organizations with a visual tool to analyze and improve their processes. By mapping out the flow of materials and information, businesses can identify inefficiencies, bottlenecks, and areas for improvement. This service facilitates a structured approach to enhancing process performance, enabling organizations to create more value for customers while minimizing waste. 

Key Benefits: 

• Enhanced Visibility: Gain a clear understanding of the entire process flow, including value-adding and non-value-adding activities.
  
  
• Identification of Waste: Spot inefficiencies and redundancies that can be eliminated, leading to streamlined operations and cost savings.
  
  
• Improved Collaboration: Foster teamwork across departments by visualizing how different functions interact, promoting a culture of continuous improvement.
  
  
• Data-Driven Insights: Use the information gathered during mapping to make informed decisions and prioritize improvement initiatives based on impact.
  
  
• Faster Lead Times: Optimize processes to reduce cycle times, resulting in quicker response to customer demands and improved service delivery.

Send a Request

Rapid Improvement Event (Kaizen) Events Facilitation 

Overview:

Our Rapid Improvement Event (Kaizen) Events Facilitation are designed to help organizations implement Lean methodologies quickly and effectively. These team-based initiatives focus on the rapid identification and elimination of waste in specific areas of your operation. Our facilitators guide participants through a structured three-phase process: Planning and Preparation, Implementation of the Event, and Presentation, Celebration, and Follow-Up. This service ensures that teams are equipped with the necessary tools and methodologies to drive meaningful and sustainable improvements. 

Key Benefits: 

• Focused Waste Elimination: Quickly identify and eradicate non-value-added activities, leading to improved efficiency and productivity in targeted areas.
  
  
• Comprehensive Framework: Follow a structured approach that facilitates effective planning, execution, and follow-up, ensuring that all aspects of the improvement event are covered.
  
  
• Team Empowerment: Encourage active participation and ownership among team members, fostering a culture of collaboration and continuous improvement.
  
  
• Sustainable Impact: Establish systems for ongoing improvement, ensuring that gains are maintained and further enhancements are pursued after the event.
  
  
• Expert Facilitation: Leverage the expertise of our experienced facilitators who provide coaching and support throughout the event, tailoring the approach to fit your organization’s specific needs.

Send a Request

FMEA Facilitation

Overview:

Our FMEA (Failure Modes and Effects Analysis) Facilitation service is designed to guide teams through the systematic process of identifying, analyzing, and mitigating potential failures in processes or products. Through expert facilitation, we help your team assess risk factors and prioritize actions to reduce or eliminate the impact of failures. This structured methodology ensures that potential issues are proactively addressed, leading to improved product reliability, process safety, and overall quality. 

Key Benefits: 

• Risk Identification and Reduction: Proactively identify failure modes and their effects, ensuring early detection and prevention of potential problems.
  
  
• Structured Problem-Solving: Utilize a step-by-step approach to systematically evaluate risks, prioritize critical failure points, and develop actionable mitigation strategies.
  
  
• Cross-Functional Collaboration: Engage team members from multiple departments to gain diverse perspectives, improving the depth and accuracy of the analysis.
  
  
• Improved Reliability and Quality: Enhance the reliability of your processes and products by addressing high-risk failure modes before they occur.
  
  
• Expert Guidance: Benefit from experienced facilitators who ensure the FMEA process is thorough, efficient, and aligned with your specific organizational goals.

Send a Request

Point Solutions

Overview:

Point Solutions is designed to help small and medium-sized businesses address specific, complex, or multi-variable problems they may not have the resources to solve on their own. TMAC offers a team of experienced engineers who can be called upon to troubleshoot and resolve a wide range of challenges. Whether your organization is facing a persistent issue or simply lacks the time and resources to dedicate to finding a solution, TMAC is uniquely equipped to provide targeted, effective assistance. 

Key Benefits: 

• Expert Problem Solving: Leverage TMAC’s engineering expertise to resolve difficult or persistent issues in your operations.
  
  
• Resource Efficiency: Access specialized support without needing to dedicate your own resources to time-consuming problem-solving efforts.
  
  
• Tailored Solutions: Receive customized, targeted solutions that address your organization's specific challenges.
  
  
• Timely Resolution: Solve complex problems quickly, minimizing disruptions to your business operations.

Send a Request

Shingo Criteria Assessment

Overview:

Our Shingo Criteria Assessment service is designed to evaluate your organization's alignment with the Shingo Model, a globally recognized framework for achieving operational excellence. Through this comprehensive assessment, we analyze your company’s systems, behaviors, and results based on the Shingo Guiding Principles. The evaluation helps identify areas of strength and opportunities for improvement, providing clear, actionable insights for driving a culture of continuous improvement. Our expert team works closely with your organization to develop a roadmap for implementation Shingo principles into your operations and achieving sustainable excellence. 

Key Benefits: 

• Holistic Evaluation: Receive an in-depth assessment of your organization's alignment with the Shingo Model and Guiding Principles.
   
• Improved Operational Excellence: Identify gaps and develop strategies to drive continuous improvement and long-term success.
  
  
• Behavioral Insights: Understand how leadership and employee behaviors impact performance and align with organizational goals.
  
  
• Tailored Action Plan: Get a customized action plan to implement Shingo principles and foster a culture of excellence.
  
  
• Sustainable Results: Build a foundation for ongoing success by aligning systems and behaviors with desired outcomes.

Send a Request

Plant & Warehouse Layout Optimization

Overview:

Our Plant & Warehouse Layout Optimization service is designed to help organizations address inefficiencies caused by poor facility layout. Ineffective layouts can lead to excess handling, increased inventory, slow processing speeds, and communication barriers. Through a detailed analysis of your current layout, we develop a tailored plan to optimize the flow of materials, minimize resource waste, and improve overall productivity. Whether you're redesigning an existing facility or planning an expansion or relocation, we ensure that your layout is aligned with Lean principles to support efficient operations and fast product movement. 

Key Benefits: 

• Increased Efficiency: Minimize unnecessary handling, inventory, and delays by streamlining the flow of materials and products.
  
  
• Improved Process Speed: Achieve faster throughput and production by designing a layout that supports optimal work sequences and material flow.
  
  
• Resource Optimization: Make the best use of your existing space or plan an efficient layout for new expansions or relocations.
  
• Enhanced Communication: Facilitate smoother communication and coordination between departments and workstations by reducing layout bottlenecks.
  
  
• Tailored Solutions: Benefit from a proven methodology adapted to your unique operational environment, ensuring maximum velocity of products through the system.

Send a Request