Operations - Lean

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Lean Manufacturing

At A.T. Kearney we view manufacturing as a system. To make the system work efficiently all elements of the cycle must be synchronised to meet customer demand.

The process starts by developing a clear understanding of what drives customer value and demand, identifying essential processes which deliver value to the customer and streamlining them by eliminating waste. This is achieved through a combination of cross-functional workshops and a suite of over forty Lean and SixSigma tools.

A series of workshops are built into the process, which aim to bring manufacturing employees at all levels into alignment with the expectations of them, a process which helps build a culture of continuous improvement.

Key deliverables include:

  • Definitions of business process flows and metrics
  • Comprehensive lists of profit improvement initiatives
  • Defined action plans for implementation
  • Clear definitions of key responsibilities and targets
  • Client teams committed to delivering the plan

For more information on how we can help you,
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Optimising operations to deliver the customer value proposition at the lowest possible cost Eliminating waste and streamlining manufacturing processes to deliver only what customer values Applying and tailoring the best of lean methodologies and tools to the service sector Focusing efforts on tackling strategic issues rather than incremental process improvements firms can substantial financial and strategic gains Supply Chain Operating Model at how businesses need to structure themselves to win in an increasingly Global environment Open collaboration and tighter Integration across the entire supply chain can reduce costs, improve time to market, increase efficiency and enhance customer satisfaction Sales and Operations Planning (S&OP) aims at balancing supply and demand in order to minimise inherent variability within the system and financial impact Complexity Management deals with managing complexity in areas of product portfolio, customer portfolio, locations / sites and processes Customer Integration helps tailor Supply Chains to maximise availability to customers and therefore be a major lever for top line improvements Strategic Sourcing enables an organisation to match its supply base performance with its business requirements financial discipline A.T. Kearney’s Assessment of Excellence in Procurement enables procurement organisations to drive their performance to world class levels Advanced procurement category solutions to enable clients to achieve economic benefits whilst enhancing overall supply base performance The world-leading tool to determine the appropriate strategy for every procurement category by addressing supply and demand conditions Physical Supply Chain projects are aimed at most effective alignment of the operational footprint with current and future business imperatives Reducing the capital requirements by focusing on stock management and financial discipline Optimising the end-to-end network using a combination own or third party tools as appropriate Driving excellence within a site operations through a mix of Lean and other performance enhancement tools