LEANMAP Operations Consulting
Operations Consulting and Lean Management for worldclass Efficiency


Way to world-class Efficiency

The lean transformation program delivers implemented improvements in speed, quality, and efficiency. It addresses the structure, skills of people, processes, and support systems simultaneously to achieve a sustainable level of operational excellence. Expected impact is a double-digit improvement across the entire scorecard.

Lean Transformation Program (LTP)

  • Purpose: shortening order-to-cash cycle to achieve operational excellence
  • Application: when competitiveness is eroding and losing market share
  • Process: applying Flow+Takt+Pull+Leveling to remove inefficiencies
  • Duration: 6-12 months
  • Deliverable: implemented improvements, trained people to sustain them
  • Impact: improvements in speed, quality, and delivery at lower inventory:
  • 10-30% when some lean principles are being applied already
  • 30-50% when starting the lean journey from a traditional base
  • Result: significantly improved competitiveness from faster delivery and lower cost

Impact across Scorecard

  • Quality – customers get what they need faster, more reliable, at higher service levels
  • Value – unnecessary activities/features are being removed, reducing cost for provider
  • Flexibility – less waste allows adapting more quickly to changing customer-demand/taste
  • Inventory – pulling to demand reduces inventory while increasing visibility and flow
  • Productivity – better utilization of labor, machines, and space improves cost and ROA

Program Rollout Specifics

  • Covers the entire work-stream end-to-end, including support and feeding processes
  • Takes 2 months for diagnostics and design + 4 months implementation and handover
  • Transformation is completed after 6 months, but most take 12 months to be fully stable
  • Three losses are targeted for elimination: Waste (Muda), Variability (Mura), Stress (Muri)
  • Four techniques are applied to achieve Just-in-Time JIT = Flow + Takt + Pull + Leveling
  • Spot-applications show first results after a few days (demonstration to achieve buy-in)
  • The transformation follows Leanmap's 5D process to control implementation and impact
  • Long-term goal of the program is to make 'lean' a part of the organizational DNA
  • The program is fully scalable from spot-workshop to value-chain redesign

Key Success Factors

  • Vision, purpose, strategy have been communicated and understood by key people
  • Senior management is committed to free-up required resources to execute the program
  • Cross-functional leadership-team covers all critical core and support functions
  • Members of the team are ready to spend 50% of their time to execute the program

About Lean Basics

  • LEAN is the most effective way to satisfy customer-demand at lowest cost
  • Lean creates FLOW in the order-to-cash cycle across the entire value-chain
  • FLOW happens when barriers are removed and processes work in concert
  • WASTE is a product, feature, step, activity that customers are not willing to pay for
  • Lean PULLS value through the system, while increasing speed and lowering cost
  • VALUE is a product, feature, feeling or activity that triggers a BUY-decision
  • PULL means configuring and controlling resources solely by customer DEMAND
  • All systems have LOSSES, inefficiencies from WASTE, STRAIN, UNEVENESS
  • Reducing those LOSSES creates a competitive advantage in any business
  • LEAN TOOLS are tactical and operational, only effective with long-term philosophy
  • LEAN ENTERPRISE is the end-result when applying Lean across the entire model

Results from the Program

Our clients see the impact in significant reductions in cost, inventory levels, labor content, defect levels, and lead-times. Results from transforming a electronic assembly plant with 2000 FTE:

  • 50% less inventory
  • 50% shorter lead times
  • 75% shorter setup times
  • 15% higher capacity
  • 25% higher operating margin

A traditional batch-&-queue manufacturer can expect 30-50% cost-savings from a combination of lean transformation, flexibilized production, revamped supply-chain, and quality-driven management. Impact in service processes is even higher; 50-80% improvement is common when starting from a traditional model.

Lean Design and Implementation, what we can do for you

  • Plant configuration, cleanroom-design and workstation-layout
  • Production cost-reduction program – material, labor, overhead
  • Design of mixed-model assembly line and manufacturing cells
  • Efficiency and capacity-improvement reconfiguring layout and flow
  • Easing labor-shortages through standardization and manning systems
  • Make-vs-Buy modeling – considering quality and total cost over lifecycle
  • Advising on alliances and joint ventures with partners overseas
  • Yield and capacity improvement for existing equipment
  • Overall equipment effectiveness (OEE) improvement
  • Advising on maintenance strategies to increase up-time reliability (TPM)
  • Alignment of processes to rationalize and revamp the supply chain
  • Supply optimization through supplier selection and supplier management
  • Quality management processes and systems

Contact us to support your journey to world-class efficiency – 'Navigating to Results'.



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