Business Process Re-Engineering

Many companies want to implement lean principles into their business processes and practices but this can be a daunting task. I have extensive experience (18 years) in doing this plus a considerable number of tools, templates, and methodologies which might be plugged in quickly.

Examples of re-engineered business processes

  • Yearly Business Planning One example yielded a 60% reduction in work effort. Another yielded an opportunity to easily adjust the plan at any time during the year.
  • Supplier Part Delivery One example improved on-time delivery from 20%-40% late parts to less than 1% in less than one year.
  • Site Housekeeping In this project, expense was reduced 30% to benchmark levels with full UAW employee participation and no grievances filed.

Management with visual control

There are some simple tools and methodologies to implement green/red marking of task status which greatly reduces waste. Some of these tools eliminate the need to write minutes of meetings and executive summaries. The most notable tool is the Master Summary Report which is described in the presentation:  Lean Project Management Tools– General Purpose Templates. Click here for the PDF file.

Dynamic integration

Applies to multi-functional area projects where changes during the execution of the project must be adapted to in real time. There are team norms plus simple tools like the Master Summary Report and the Issue Register that are general purpose tools to meet this need. These tools and methodologies have been applied in the following situations:

  • Production launch
  • Product development
  • Facility transition projects
  • Proposal generating projects

All of these examples eliminated the need to write minutes of meetings and executive summaries. For more information on Master Summary Reports and Issue Registers, see the presentation Lean Project Management Tools– General Purpose Templates. Click here for the PDF file.

Value stream mapping

For business processes that are complex or require buy-in from multiple functional areas, value stream mapping is a desirable approach. One application was to a product development process which yielded a 50% reduction in lead time for the customer. Another example helped and organization triple their capacity without requiring an increase in operating cost. This latter example is in the public domain. See DuPage Habitat for Humanity – Lean Implementation Case Study.  Click here for the PDF file.