Eliminate the costs of excess inventory, manufacturing lead-time, floor space, production and processing
Generating more quality output with less resources and costs is the key to success in today’s competitive environment. Impactiva’s Lean specialists will work with you to establish, implement and maintain a Lean production system at each of your factories that removes waste while increasing quality, productivity, on-time delivery, flexibility and manufacturing capacity.
How it works
Your customized Lean Transformation Program will focus on the systematic elimination of waste and implementation of concepts of continuous flow and customer pull.
To achieve this goal, first we’ll hold a meeting to sync your strategic operating goals and strategic Lean goals, as well as nominate a Lean Program Sponsor at each of your suppliers. A detailed, two-day Lean Excellence Assessment will follow, rating the current operations of each supplier site. Next we’ll gather data through interviews and floor inspections, assess opportunities for improvement, clean-organize all factory work stations, and implement managing for daily improvement.
Our Lean Consultant will then work with your site’s team members to align your strategic Lean goals with specific waste reduction project plans, which will be co-implemented by an Impactiva-trained factory process engineer at each of your factories with our assistance and oversight. Subsequent monthly reports will be provided of project status, waste eliminated and savings achieved.
In addition, we’ll require that your supplier owners, top managers and senior supervisors attend a detailed learning and coaching program to fully understand the Lean tools and goals, as well as their responsibilities. Operations leadership at each supplier site will attend a 24-hour Lean Transformation Learning Program, while top supplier leadership will attend a 44-hour Change Leadership Coaching Program. This learning will ensure that the improvements made in your Lean Transformation Program are sustained, maximizing long-term efficiency and profitability.
Impactiva’s Lean Transformation Program will provide sustained optimization of your supply chain by eliminating waste thereby increasing quality, productivity, flexibility, and manufacturing capacity.
Eliminate waste throughout your factories’ manufacturing processes. Produce significantly more with the same or less resources. Impactiva can help you turn around your manufacturing organization and enjoy the following benefits:
- Manufacturing capacity (increased throughput with the same resources)
- Labor productivity
- On-time delivery
- System flexibility (ability to react quickly to sudden changes in demand)
- Waste (material and finished product rejects, % of rework, etc.)
- Manufacturing lead-time
- Floor space
- Work-in-process inventory
- Working capital
TEAM AT YOUR SERVICE
The following Team will support the activities required to perform the Service:
- Lean Consultants who have a proven track record of lean manufacturing implementation delivering breakthrough results.
- Lean Transformation Facilitator who will facilitate the Lean Transformation Learning Program given to the operations leadership at each Supplier Site.
- Change Leadership Coach who will coach the Supplier’s top leadership team so that they are aligned and focused on the role they need to play to fully support the Lean Transformation Program.
- Lean BU Leader responsible for running the Lean Business Unit.
- R&D Team responsible for gathering Lean best practices and designing new Lean improvement processes.
- Learning Team responsible for imparting lessons to the entire IMPACTIVA Lean Team for all new processes and procedures developed by the R&D Team.
DEFINITION OF STANDARDS
We will meet with you to understand your company’s strategic goals for the next three to five years in order to then identify and agree with you, your Lean strategic goals. This is the beginning and an extremely important part of your supply chain’s lean transformation process; it is the seed that will grow into your Lean Manufacturing Transformation Program.
IMPACTIVA AT THE FACTORY
We proceed to visit each factory to perform an in-depth two day assessment which defines their current level of Lean excellence. Next, we develop a detailed value stream map to identify a factory’s ‘current state’ and design and agree upon the first ‘future state’, based on your Lean strategic goal priorities.
We then start each factory’s transformation by laying a solid lean foundation based on implementing 5S (Sort, Straighten, Sweep, Standardize and Sustain) and Managing by Daily Improvement (MDI) systems. During this time, we will be consulting with factory team members to collect operational details which will serve as the basis for the return on investment calculation of the first five kaizen events, chosen based on the priority stated within your strategic Lean goals. The ROI of these kaizen events will always exceed 200%!
After completion of each kaizen event, we build process execution discipline by training and supporting the factory’s process engineer to maintain the work standards and standard work of each transformed process thus ensuring continuous improvement.
From day one at each factory, we will provide a leadership development platform that consists of Lean Transformation Learning and Change Leadership Coaching. Lean Transformation Learning is designed to train the operating management at each factory on the basics of Lean manufacturing techniques. The Change Leadership Coaching aims at enhancing the long term vision and leadership skills of each factory’s top leaders in order to support their Lean Transformation Program far into the future.
OUR CONTRIBUTION TO CONTINUOUS IMPROVEMENT
As a final stage of the Lean Transformation Program, we build process execution discipline by training and supporting the factories’ process engineers so that they are able to maintain executed processes and controls and create new ones, thus ensuring continuous improvement and long term sustainability.
WHY IS IMPACTIVA DIFFERENT?
EXPERIENCE AND EXPERTISE
As the world’s leading quality assurance company in the footwear, apparel, leathergoods and outdoor gear industries, Impactiva brings an unmatched team of industry focused Lean experts that will quickly turn around your factories’ operations helping you to save from the first day with a return on investment superior to 200%!
DETAILED UNDERSTANDING OF YOUR OPERATION
Our Lean Consultants specialized in the lifestyle industry will work with you and your factories to increase their productivity and on-time delivery, reduce lead-times, inventories, operating costs, rejections, and space utilization.
To safeguard the continued success of our Lean Transformation Programs, we provide learning seminars and one-on-one coaching to the leaders of each factory thus ensuring continuous improvement far into the future.