Lean Manufacturing

Lean simply put eliminates waste and delivers
more value to customers

Lean Manufacturing

‘Lean Manufacturing’ is a relentless pursuit to eliminate “waste” in all forms. This means anything that consumes resources but does not add value to the organization or its customers must be eliminated or simplified. A company pursuing Lean aims to achieve ‘flow’ in every activity right from customer requirement gathering to order fulfillment and cut down lead time and cost by eliminating wasteful activities i.e. activities that add burden of time and cost but no value as perceived by customers. Born at Ford in the early 1900s and later perfected at Toyota, Lean played a crucial role in Japan’s post World War economic miracle and to this day is at the heart of Japan’s competitiveness. Some of the benefits of Lean are dramatic reduction in lead time, significant increase in productivity, improvement in quality and inventory turnover resulting in superior customer satisfaction and higher return on investment.

What We Do

SSA’s Lean deployment approach involves a systematic approach of studying the client’s ‘current state value stream’ i.e. how information and materials flow within the organization and its supply chain, identifying flow inhibitors and wasteful activities and thereby designing ‘future state’. The goal is to evolve an ideal state where information and materials flow unhindered from one value adding step to the next with the fewest possible steps leading to dramatic improvements in lead time, delivery and cost performance. The core idea is to maximize customer value while minimizing waste thus creating maximum shareholder value. Lean helps create robust processes that need less human effort, less space, less capital, and less time to make products and services at far lesser costs and with much fewer defects, compared with traditional business systems.

How We Help Clients

SSA offers a proprietary 4D approach to Lean deployment. 4D stands for Diagnose, Design, Deploy & Develop. In brief — the Diagnose Phase involves baseline performance analysis, section of prioritised improvement areas and agreement on improvement themes and benefits. The Design Phase involves deep-down analysis and design of future-state based on a detailed value stream analysis, application of best practices in terms of layout, flow, information exchange, order fulfillment strategies and supply chain design. The Deploy Phase culminates into a set of future state recommendations aimed at maximising value and minimising waste in the form of time, cost and resources. Finally the develop phase involves horizontal deployment, scale-up and internalising of knowledge and best practices. SSA believes in hand-holding and partnering with its clients in every step of the transformation journey in order to maximise the likelihood of success.

Examples of our work