Lean diagnostics and Value Stream Mapping (VSM)
We map material and information flow end to end and draw the current and future states. Where lead time is lost becomes visible on a single page.
Solutions · 03
Lean Manufacturing & Lean Transformation Consulting
Lean manufacturing is a management approach that makes every step that adds no value for the customer (waste) visible and removes it, so work flows faster, with less inventory and less effort. We apply Lean on the shop floor, with your teams, on real products and real lines.
- 25+
- years on the shop floor
- 7
- countries
- 200+
- Kaizen and belt projects (Fega Partner)
What is lean manufacturing?
Only a small fraction of the time a product spends in a plant actually adds value to it. The rest is spent waiting, being moved, sitting in stock or being reworked. Lean manufacturing makes that time visible and reduces it step by step.
A lean transformation is not a list of tools. When 5S boards are put up and forgotten, or Kaizen stays an event instead of becoming part of daily work, nothing changes. That is why we tie every tool to a concrete flow problem you want to solve, and stay on the shop floor until it is part of the teams' daily routine.
Scope
What the work covers
Kaizen events
In a focused area, over a few intensive days, we solve the problem with the team on the shop floor and measure the result before the week is out.
Quick changeover with SMED
We shorten changeover times so you can run smaller batches and produce more flexibly.
TPM and OEE
We measure equipment losses with OEE and reduce downtime through autonomous maintenance, planned maintenance and focused improvement.
5S and visual management
We make the workplace orderly so deviations are spotted at a glance, and keep it that way with regular audits.
Flow, pull systems and kanban
We design and implement flow and kanban systems that cut buffer stock and link production to real demand.
How we work
How a lean transformation unfolds on the shop floor
- 1
Gemba: observing on the floor
We start where the work is done, not at a desk, and see flow, waiting and problems first-hand.
- 2
Value stream map
We map the current state with data and pinpoint where waste is concentrated.
- 3
Future state and priorities
We design the flow you want to reach and sequence the projects that will get you there.
- 4
Kaizen and pilot line
We quickly implement the first improvements on a chosen line and measure the results.
- 5
Standard work and roll-out
We standardise what works and carry it over to other lines and departments.
What changes?
- You know where lead time is lost and act on it.
- Buffer stock and work in progress fall, so cash is not tied up on the floor.
- Changeovers get shorter and you respond faster to small orders.
- Teams start solving problems in their own areas, on their own.
Who is it for?
- Manufacturers working with long lead times and high buffer stock
- Lines that lose flexibility as product variety grows
- Plants struggling with equipment downtime and low OEE
- Organisations that have tried Lean before without lasting results
Frequently asked questions
Common questions.
What is lean manufacturing?
Lean manufacturing is a management approach that removes activities that add no value for the customer, known as waste, so production takes less time, less inventory and fewer resources. Its roots are in the Toyota Production System.
What are the types of waste in Lean?
Lean thinking commonly defines eight types of waste: overproduction, waiting, unnecessary transport, over-processing, excess inventory, unnecessary motion, defects (rework and scrap) and unused employee talent.
What is Kaizen?
Kaizen is Japanese for “change for the better” and refers to small, continuous improvements. A Kaizen event is a structured exercise in which a team works intensively for a few days on a specific problem and implements a solution on the shop floor.
What is Value Stream Mapping (VSM)?
Value Stream Mapping is a Lean tool that shows the material and information flow of a product, from raw material to customer, on a single map. By separating value-adding from non-value-adding time, it helps set improvement priorities.
Is Lean only for manufacturing?
No. Lean principles are also applied in logistics, warehousing, maintenance, purchasing and office processes. Most of our experience is in manufacturing, but we also work on the processes that support it.
Led by
Abbas Erdenal
Lean Six Sigma Master Black Belt · Founder of Fega Partner
More than 25 years on the shop floor, over 1,000 improvement projects and programmes delivered in seven countries. Abbas Erdenal personally leads every consulting engagement and training.
About Abbas Erdenal