Lean, developed from Toyota's breakthrough Just-In-Time production system, is more than manufacturing tools. In this competitive business world, no longer are manufacturers or service providers setting the price; instead, the market sets the price, and market players deliver their goods at minimum cost to sustain profits. Lean comes in to minimize the cost of producing the goods and services, equipping companies with bigger competitive advantage.

Lean transformation enables clients to achieve their best performance by reducing-and in many cases eliminating-non-value-added processes. It cuts costs and time to market, allowing clients to get ahead of their competitors in gaining market share, resulting in enormous financial profitability.

We believe that implementing lean integrates strategy and operation, and makes a powerful weapon to help sustain profit and growth.

HOW WE DO IT

Many companies adopting lean in their operation expected great outcomes but was then only to see performance deteriorates way faster than it improved.

We believe that performance can be sustained only if the three crucial factors are addressed properly and simultaneously.

• Operating system-assets and resources are configured to bring value to their customers. All non-value-added process in between should be eradicated.
  
  
• Management system-formal systems and structures should be upgraded to align with the operating system.
  
  
• Mindset-People of the whole corporation should be engaged to the system, and be equipped with skills to perform better.

In every Lean project, we work with clients in analyzing their current situation and performance, setting their goals to be achieved through Lean, and identify changes to be made in the operating system, management system, and mindset of people.

In most cases, companies fail to sustain the performance gained by implementing Lean due to a virtual neglect of the engagement of their people. We consider awareness and training programs a crucial factor of the successful implementation of Lean.

TQM takes a five-step approach in helping our clients implement Lean.

Preparation selecting the right consultants into the team, setting up a lean task force for clients, and gathering the right information and resources.

Analysis involved identifying the root causes of under-performance through site visits, archival data analysis and problem-solving. It includes also quantifying room of potential improvement.

Design comprises of the redesign of workflow, physical layout, and information flow. It may include also a trial run of implementation in a selected small area of the corporation.

Implementation of the new way of working and thinking brings to the business room for growth in performance and profitability.

Control means the monitoring and fine-tuning of the mechanism, which may involve a spread out of the system to other sites of the corporation.

RELEVANT CASES

Check out our experience in implementing Lean for our valued customers as follows:

LEAN TOOLS

Check out also different aspects and tools of the Lean approach, including Lean Manufacturing, Lean Servicing, Kaizen, 5S, Balanced Scorecard, Poka Yoke, Kanban.