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Process Reengineering & Lean Six Sigma

Rethinking and redesigning your business practices for improved efficiency. As opposed to improving an existing process, this service focuses on creating a new, more effective processes. Drawing from our team of Lean Six Sigma experts, we work to recognize where problems arise in current processes. We then deconstruct procedures and build new and improved processes from the ground up.

Lean Six Sigma is a combination of two powerful methods of reducing waste and improving efficiency 

  • Lean: Reduces by streamlining processes 
  • Six Sigma: reduces defects by effectively solving problems. Six Sigma is about practices that help you eliminate defects and always deliver products and services that meet customer specifications
  • Lean Accelerates Six Sigma by solving problems and improving processes to be faster and more efficient. “Real World” projects rarely fit neatly within one bucket or the other – TPG practitioners are well versed in both, to apply the right set of tools at the right time to your organization. 
  • Highest quality, lowest cost and shorted lead times 

We can apply this methodology to both back office and manufacturing settings 

Reasons to improve the efficiency of your organization: 

  • Increase productivity and the quality of processes the organization supports
  • Knowledge sharing, especially customer information
  • 80%+ of quality issues come from upstream input processes in this business
  • Align company and individual vison
  • Remove silos
  • Improve morale and instill better communication 

We first map out your current processes to identify areas of improvement

Current State Future State
- No time to build the business or improve
- Just maintaining the business and keeping it afloat
- Too much time catering to crises and fighting fires
- A lot of non-value-added actions
- Not enjoying your work
- More time to build the business
- Less time catering to crises, problems are addressed at the root cause
- More value-added activities
- Enjoy work and life

We use a number of Lean Six Sigma best practices to make your enterprise as lean as possible ​

  • Remove what is not needed and keep what is needed. 
  • Arrange essential items in order for easy access
  • Keep things clean and tidy, no trash or dirt in the workplace 
  • Establish standards and guidelines to maintain a clean workspace
  • Make the above a habit and teach others to adhere to the standards

Cellular Layout

An approach that requires equipment and workstation to produce a product

This approach facilitates continuous flow of production and provide flexibility to produce variety of low demand products

Traditional Layout

Cellular Layout

  • Straight lines often make it hard to balance tasks because work may not be divided evenly and visibility / accountability is hidden
  • Improved layout – in U shape, workers have better access. Combined w/ cross training, many opportunities for efficiency

Kanban

Scheduling system used in manufacturing to help companies improve their production process. It is a system of continuous supply of components and parts such that workers have what they need, where they need it and when they need it. It is a method for developing products with an emphasis on just-in-time manufacturing process by limiting the amount of inventory in the process by acting as an authorization for produce less inventories. Essentially, it exposes system problems through visualization

Cycle Time improvements

Using lean techniques to optimize time required for workers to complete one cycle of a process. We eliminate non-value-add steps of the process and improve information flow.

Pull System

Production and distribution are demand driven. This method is focused on the customer because it produces inventory in anticipation of the customer needs versus anticipating their orders. It is effective in dealing with stable demand

DMAIC Framework

  • Define measure, analyze, improve, control