Lean Process Improvement Projects
Our approach to Process Improvement activities to solve the problems follow seven main steps:
All of our projects start with an initial diagnostic phase which entails the first 6 steps outlined below. We offer the Diagnostic Phase as a independent initial project to identify the improvement potential and provide a basis for our clients to decide whether the suggested implementation project fits into their business strategy and provides the desired ROI. Depending on the size and scope of the project this phase will require 1-2 of our senior consultants for about 11 work days and concludes with a Diagnostic Presentation.
Initial Diagnostic Package:
- Scoping Phase / Pre-Project Phase In the first phase we clarify the framework for our activities by defining the scope and deliverables, roles and responsibilities, resource and capacity plans and budget. Additionally the change champions have to be defined to start participating already in the early stages of the project planning. The Scoping Phase ends with the official Project kick-off meeting.
- Value Stream Mapping / Analysis It always starts with a process walk and a process mapping exercise to understand the end to end flow of the individual process steps and the related information flow which controls the process. With analysis tools like the 7 Wastes, Variance Analysis or Constraint Analysis (OEE) we will identify the shortfalls of the current process and highlight the main contributors to the high level problem statement.
- Future State Definition Together with the process owners we will establish a redesigned target process which aims to eliminate the problems and improve the process in either lead-time, through-put, cost or variance (quality).
- Define Change Phases The next step is to define steps of transformation which should show the path from the current state to the future state condition. These steps are usually drawn up as transition process maps showing partially transformed process conditions to explain the change activities.
- TIP The transition maps are forming the basis to generate an improvement plan (Tactical Improvement Plan or TIP) which will become the guiding project plan for the change project.
6. Transformation The implementation phase will follow the improvement plan with regular steering reviews ensuring that business focus and resources are sufficiently in place and that progress is made aligned with the projected plan. Required resource and structure changes are usually the first activities to prepared for the change activities.
7. Sustainability After implementations are completed a monitoring phase will follow to allow for controlled intervention if additional coaching / training is required.