Craig Corsi

Operational Excellence Services

An Approach Customized for Your Company

Our Consultant provides onsite training or consulting tailored to your company needs. Whether you’re taking the first step or already have an established lean / continuous improvement program, we can provide your organization with the training and implementation tools to improve operational excellence and help you achieve bottom line results.

Onsite services include

Value Stream Mapping
An in-depth analysis of a major product or services value stream within your company. The intent is to identify and eliminate the “waste” within the process to realize improved efficiencies and productivity. Typically implemented on-site with a selected project team, this highly effective tool is encouraged as an initial step for those companies just starting out in their lean journey.

Plant Layout and Design – Production Preparation Process (3P)
3P is often referred to as “design for manufacturability”. 3P rapidly creates and validates potential product and process designs that require the least amount of time, materials and capital resources. Companies who are moving their operations, expanding their facility or simply want to improve their current layout are classic candidates for these services.

Set-Up Reduction i.e. Quick Changeover, Single Minute Exchange of Dies (SMED)
Set-up is defined as the amount of time that lapses between the last piece produced of the current order until the first good piece is produced from the next order. Dependent upon how long your set-ups usually take, we can assist you in reducing that amount of time usually by 50%.

Performance Management (Key Performance Indicators)
“You cannot manage or improve what you do not measure”. Developing and implementing the appropriate metrics or KPIs is critical for the success of your business. We’ll help you create and implement an effective lean performance measurement system geared towards driving the right improvement behaviors.

The Kaizen Method
Transform your company or operation by stimulating action, building velocity, and sustaining momentum. You will learn how to plan effective process improvements, use influence and persuasion to overcome barriers, and learn the proven tips and techniques for sustaining change.

Lean Administration
LEAN Office helps companies with any type of administrative function to streamline information flow, the gathering of it while improving the movement and storage of information. Just as LEAN is typically applied to the factory floor, LEAN Office focuses on reducing total cycle time from the time between when quotes are requested, orders are placed and payments are received.

Operations Assessment
We can conduct an onsite assessment by evaluating the current business climate focusing on; Improvement Readiness, Culture, Leadership, Key Performance Indicators and Return on Investment. The assessment will provide an overview of the findings and make recommendations for improvements in the areas of; process efficiency, worker productivity, product/process flow, inventory levels, workplace organizations, safety, employee morale and company performance.

3S, 5S or 6S Workplace Organization
Reduce waste through a systematic application of the 5S System (Sort, Set in Order, Shine, Standardize, and Sustain). Onsite training and implementation is customized to be applied to your specific business. Companies typically see immediate results through improved quality outcomes, less variability with work standardization, decreased changeover times, improvements in safety, reduced cycle times, reduced machine down time as well as an increased employee morale.

Kanban / Pull Systems
Explore the process of designing and implementing Pull Systems/Kanban at your company. Pull methods control the flow of resources in a production process by replacing only what has been consumed and employs customer order-driven production schedules based on actual demand and consumption rather than forecasting. Implementing Pull Systems can help you eliminate wastes of overproducing, lessens material handling, frees up space, reduces inventory and improves cash flow all with the intention of getting product to the customer faster.

Building a Culture of Continuous Improvement
This is a program geared to help a company who is committed to developing a culture of continuous improvement. Using the teachings of Paul Akers, author of the book “2 Second Lean”, the consultant will facilitate group discussions and guide your company through the successful implementation of this program. Learn how to take the necessary steps to empower and engage the workforce to create an environment of learning, sharing, and growing. This program can accelerate the transformation of your culture by years.

Cellular Design for Manufacturing
Learn how linking and balancing process steps to create flow can reduce process lead times by as much as 95%, work-in-process inventory by 90% and floor space utilization by 50 to 75% while increasing productivity by 40% or more.

Other services

Problem Solving Tools (A3, 5Whys, Fishbone Diagram, DMAIC)
Developing Standard Work
Cost Reduction Strategies
Continuous Improvement Coaching & Mentoring
On-Site Lean / Continuous Improvement Programs

Training Programs

Introduction to Lean Principles
Participants learn the principles of lean for a typical manufacturing environment. Simulation exercises are used to reinforce the tools and concepts by participating in “hands-on” training to better grasp and understand the tangible benefits when lean methods are successfully implemented.

3S, 5S, 6S Workplace Organization
The 3S, 5S or 6S System is a series of activities designed to improve workplace organization and standardization. Participants learn the concepts and then gain firsthand experience by transforming a cluttered, disorganized production area into a clean, organized, and orderly workplace.

Lean / Continuous Improvement Specialist Certification
Gain knowledge of LEAN principles through hands-on training, engaging classroom exercises, and practical assignments that pertain directly to your business. This program is 4 weeks long and is presented once per week to allow for the completion of assignments and the comprehension of topics. LEAN Champion training hours and assignments qualify for the Society of Manufacturing Engineers (SME) Lean Certification requirements.

Value Stream Mapping
Gain knowledge of this powerful, insightful and enabling tool which produces a detailed map of material and information flow, from a request for quote to order receipt through the operation’s processes until the product or service is delivered to the customer and invoiced.

Lean Overview Training
Learn how to improve cash flow and earnings through tried and true tactics such as processing error reduction, effective space utilization, and work-in-progress inventory handling reduction. Subjects covered in this 2-hour seminar include Value Stream Mapping, KanBan Inventory Reduction, and the efficiencies of 5S. This training is best suited for those individuals who have no previous knowledge of the lean concepts and need to gain a basic understanding. It is suitable for hourly employees, supervisors, managers, office personnel and executives.

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