Why Lean Manufacturing?

Lean manufacturing is a philosophy and approach that has gained immense popularity across industries for its efficiency, waste reduction, and customer-centric principles. This method focuses on minimizing waste while maximizing productivity and value, ultimately leading to improved quality, shorter lead times, and reduced costs.

Incorporating lean principles into your processes can lead to significant improvements in efficiency, quality, and overall performance.

Lean Manufacturing

Our Implementation Model

Our implementation model consists of 3 basic phases, regardless of the sector. Each phase is designed in line with the customer’s processes and needs;

Training

In lean trainings, participants learn about lean principles, waste reduction, and continuous improvement. They gain insights into identifying and eliminating various types of waste, such as overproduction and defects. Trainings often cover tools like value stream mapping, 5S, and Kanban. Participants also discover how to foster a culture of employee engagement and implement lean techniques to enhance efficiency and quality.

Implementation

Leveraging skilled teams of trained personnel in accordance with with field dynamics and guided by our consultants, lean techniques are implemented across pilot zones or field-wide. Post-implementation, benefits along with associated risks are reported to management, thus validating the system’s efficacy.

Sustainability

Ensuring the sustainability of the implemented lean technique involves regular performance monitoring, ongoing employee training, and timely adjustments based on evolving operational needs. We maintain open communication channels to gather feedback, fostering a culture of continuous improvement. By addressing challenges proactively and adapting to changing circumstances, we secure the long-term effectiveness of the lean practices.

Our Trainings

5S

The base element of lean manufacturing is standard work. It is not possible to accurately measure process standard times and therefore performance without standardization. The process that cannot be measured correctly cannot be managed and improved. The process that cannot be measured correctly cannot be managed and improved.

Especially in areas where many different people work together, the standardization process starts with 5S and visual management.

5S is the way to perfection in terms of performance, comfort, safety and cleanliness in the shopfloor and offices.

TMP

Total Productive Maintenance is a Lean Manufacturing Technique used to systematically sustain production continuity. Focusing to increase the efficiency and stability of machinery, equipment, processes and employees, the TPM aims to add company profitability and value.

TPM focuses on equipment at maximum performance according to the highest level of condition and reducing losses due to breakdowns. TPM performance is tracked with the OEE (Overall Equipment Effectiveness) trend. The goal of the TPM Course is to train leaders who can manage the integration of this system in the company.

Kaizen

Kaizen ensures participation of each individual, regardless of level and organizational hierarchy, and changes processes with suggestions from process owners. A solution oriented employee profile is created in the company by this approach. The sense of belonging of all employees to organizations becomes stronger and stronger.

The main purpose of our trainings is to ensure the active participation of all employees in continuous improvement activities. Therefore, in our workshops, the Kaizen courses are processed with real examples from the related sectors. .

SMED

SMED (Single minute exchange of die) is one of the many Lean Manufacturing Tools used to minimize losses in manufacturing processes. It is the way to change from a working product to another product effectively and quickly. Fast changing between products in SMED applied processes minimizes lot quantities and makes lean the flow.

he cost of changeover time per product is inversely proportional to the order quantity. Accordingly, the contribution of the changeover time increases as the order quantity decreases. Therefore, SMED is an indispensable Lean Manufacturing Tool in flexible production systems.

Lean Manufacturing Tools

Lean Manufacturing Tools aims to remove activities that do not add value systematically. In a lean organization, activities are organized according to the flow of works. Products that meet customer expectations pass through the manufacturing system with the minimum loss in the shortest time. The improvement in quality and speed results in a direct cost reduction, as the activities are aimed at without additional investment. All of the lean techniques are practice-oriented work done within the workshop.