Lean is applied in manufacturing as Lean Manufacturing and in services as Lean Services.

It is based on the TOTAL LEAN MANAGEMENT (TLM) Model.

  • TLM application is across the value chain, from supplier to end user
  • Objective is to increase the value-adding ratio - the ratio of the value adding (VA) to the total through put time (TPT)...focus on identification and reduction of non value adding
  • Foundations of TLM are 5S and Top Management Commitment

TLM comprises of 5 pillars, which are dependent yet mutually exclusive.

TOTAL FLOW MANAGEMENT (TFM) Pillar comprises of the following lean tools:

  • Spaghetti Diagram
  • Value Stream Mapping (VSM)
  • Product Quantity (PQ) Analysis
  • Flow Layout
  • 5S
  • Cellular Manufacturing
  • One Piece / Small Batch Flow
  • Standard Work In Progress (SWIP)

TOTAL PRODUCTIVE MAINTENANCE (TPM) Pillar comprises of the following lean tools:

  • 8 Pillars of TPM
  • Planned Maintenance
  • Visual Machines
  • Spares Management
  • Reliability

TOTAL QUALITY MANAGEMENT (TQM) Pillar comprises of the following lean tools:

  • 7 Basic QC Tools
  • 7 New QC Tools
  • Poka Yoke
  • Lean Six Sigma
  • QC Story Boards
  • Visual Standards

TOTAL SERVICE MANAGEMENT (TSM) Pillar comprises of the following Lean tools:

  • Lean Business Processes
  • Lean Inventory Management
  • Lean Spares Management
  • Lean in IT

TOTAL HUMAN MANAGEMENT (THM) Pillar comprises of the following Lean tools:

  • Lean Organization Architecture
  • Lean KPIs
  • Lean Counseling

Lean execution and sustenance methodology:

  • Preparation of Lean Strategic Roadmap
  • 5S, being the foundation tool, to be applied first, for culture building and ensuring all Lean pillars and tools to sustain
  • Top Management commitment is the key for thwarting the resistances to change
  • Lean Pillars and Tools should converge and align with the organization vision, goals, business excellence model and business philosophy
  • Continual monitoring
  • Creating Lean Themes for employee motivation
  • Recognizing and rewarding Lean efforts

ADDVALUE CONSULTING INC (AVCI) integrates and aligns all Lean pillars and tools with organization Business Excellence (BE) model in its Lean Training, Consulting and coaching modules, creating Operational Excellence (OPEX) in each and every aspect of the enterprise.

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