Lean Business & Lean Manufacturing Consultancy

CMP Solutions are lean business and lean manufacturing consultants that can help you improve your business efficiency by maximising value whilst minimising waste.

Lean Business & Lean Manufacturing

What does it look like?

- Increasing efficiencies
- Cost Improvements
- Continuous improvement
- Waste elimination
- Simplified standard work
- Optimum use of space

What are the results?

- Sustained culture of Operational Excellence
- Increased profit margin
- Facilitation of future growth
- Defect reduction
- Superior customer service
- Motivated workforce

Will lean business & lean manufacturing work for your business?

Food Processing

Manufacturing

Banking & Financial Services

Distribution & Logistics

Food & Beverage

And many more…

Lean methods/services

Value Stream Mapping

Value Stream Mapping (VSM) is a process improvement technique used by businesses to enhance efficiency and eliminate waste. It involves visualising the entire journey of delivering a product/service to customers, from raw materials to the final outcome (current state). By identifying bottlenecks, inefficiencies, and areas of improvement, Value Stream Mapping enables organisations across all industries to streamline their processes, reduce lead times, and enhance overall quality, leading to improved customer satisfaction and sustainable business growth (future state).

Kanban Implementation

Kanban is a dynamic approach encompassing inventory control for just-in-time production, visual workflow management, and scheduling within lean systems. It serves as an inventory tracker, ensuring timely part and material orders.

The 5S

5S is a method for creating a safe, clean, organised, high performance, visual work environment, that contains only what is needed, when it is needed and where it is needed. 5S is the foundation of all continuous improvement.

Poka-Yoke

Poka Yoke is a meticulous quality assurance technique utilised by businesses to prevent errors and defects in processes. Also known as 'error-proofing' or 'mistake-proofing', Poka Yoke employs mechanisms such as sensors, visual cues, or simple devices, to prevent or detect mistakes at various stages. By implementing foolproof measures (think the 3-pin plug), Poka Yoke ensures that errors are caught and corrected before they escalate, leading to enhanced product quality, reduced rework, and improved overall efficiency across diverse industries.

Root Cause Analysis

Root Cause Analysis is a systematic investigative process employed by businesses to uncover the underlying factors contributing to problems, errors, or incidents. This method aims to identify the fundamental causes that lead to undesirable outcomes by delving beyond surface issues. Through structured techniques and data analysis, Root Cause Analysis helps organisations address issues at their source, allowing for effective solutions, process improvements, and preventive measures. This approach leads to enhanced problem-solving, increased operational resilience, and sustained business growth across various industries.

SMED

SMED, or Single-Minute Exchange of Die, is a lean manufacturing technique employed by businesses to minimise equipment changeover times. By optimising the transition process from one production task to another, SMED aims to reduce downtime and enhance operational efficiency. This methodology involves streamlining procedures, eliminating non-essential steps, and utilising parallel activities to achieve rapid equipment setup. By implementing SMED, organisations achieve faster production changeovers, increased flexibility, and improved productivity, contributing to overall operational excellence.

DMAIC Process

Every process can be Defined, Measured, Analysed, Improved and Controlled. Beginning with defining the problem and measuring its current state, DMAIC delves into data analysis to uncover root causes. Subsequently, improvements are identified and implemented, followed by the establishment of control measures to sustain the gains. Following the DMAIC framework can contribute to Operational Excellence levels of efficiency through data-driven solutions, optimised processes, and consistent quality enhancements.

A3 Lean

A3 refers to a problem-solving and communication tool designed to foster collaboration and improvement within organisations. A3 encompasses problem analysis, root cause identification, proposed countermeasures, and an action plan. By promoting clear communication and structured problem-solving, A3 empowers teams to make informed decisions, address challenges, and drive continuous improvement.

What kind of results can I expect from implementing lean services into my business?

Increased Efficiency and Productivity

Potential Result

Process cycle times reduced by 20%, leading to a 15% increase in overall production output.

In Practical Terms

Average production time per unit decreased from 2 hours to 1.6 hours, resulting in a 20% improvement in efficiency.

Reduced Costs

Potential Result

30% reduction in material waste and a 15% decrease in operational costs.

In Practical Terms

In Practical Terms: Monthly material waste expenses reduced by €10,000, and monthly operational costs decreased by €15,000.

Improved Quality

Potential Result

Defect rate decreased by 50%, resulting in a 25% increase in customer satisfaction scores.

In Practical Terms

Number of customer-reported defects decreased from 10 per month to 5 per month, leading to a 20% improvement in customer satisfaction ratings.

Faster Lead Times

Potential Result

Order fulfilment time reduced by 30%, leading to a 20% increase in on-time deliveries.

In Practical Terms

Average order fulfilment time decreased from 7 days to 5 days, resulting in an 18% increase in on-time deliveries.

Enhanced Flexibility

Potential Result

Ability to adjust production based on demand changes within a 2-week timeframe.

In Practical Terms

Successfully shifted production focus from one product line to another within 10 days to meet unexpected spike in demand.

Engaged Workforce

Potential Result

40% increase in employee engagement scores based on regular surveys

In Practical Terms

Employee engagement survey scores improved from an average of 3.5 to 4.9 on a 5-point scale.

Better Communication & Collaboration

Potential Result

25% reduction in cross-departmental communication bottlenecks and delays.

In Practical Terms

Time taken to resolve cross-departmental issues decreased from an average of 3 days to 2.25 days.

Continuous Improvement Culture

Potential Result

Monthly implementation of at least two process improvement suggestions from employees.

In Practical Terms

Over a 6-month period, 12 employee-generated improvement ideas were implemented, leading to notable efficiency gains valued at €40,000.

Innovation

Potential Result

Launch of two new product variations resulting from process optimizations.

In Practical Terms

Successfully introduced two product variations within a year, generating 10% of total revenue.

CMP Case Studies

A Medical Device Manufacturer in the Midlands

"This was more than a project; it was a revolution.” In the wake of Covid-19, a midlands adhesives manufacturer faced skyrocketing product lead times. CMP […]

A Renowned Food Processing Company in the Munster Region

Project Objectives: Reduce costs. Increase Overall Equipment Efficiency (OEE). Boost capacity in the storage and dispatch area. Embed the improvements. Activities Carried Out by CMP […]

The lean manufacturing consultancy process

CMP Solutions’ Cost Reduction Calculator will provide your business with a report to identify how you can improve your costs and return on investment.

Our other core lean business & lean consultancy services

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Secure Grant Funding

Looking for EU / Government financial support for your business...

Engineering & Quality

Do you have an engineering need? Tell us the problem, we’ll engineer the solution...