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ENGINEERING AND SCIENTIFIC CONSULTING SERVICES
Lean Manufacturing, Lean Enterprise, Lean Transformation Consulting and Implementation
Kevin Kennedy & Associates offers world-class expertise in:
- Quality and Process Engineering, Quality Management, Lean Manufacturing, SPC and FMEA
- Quality System Assessment, Total Quality Management, Continuous Process Improvement, Statistical Process Control
- Medical Devices, FDA Regulatory Affairs, Quality Assurance, Product Design, Good Manufacturing Practices
- Product Warranty Analysis, Reliability Engineering, Quality Engineering, Mechanical Engineering, Electronics Product And Process Validation
- Lean Enterprise
- Lean Transformation
- Lean Consulting and Implementation
Lean practice has evolved over the years, resulting in dramatic positive transformation of organizations in all sectors of industry. While its practice has become a prerequisite for the survival of many manufacturing businesses, this methodology is beginning to find new applications in industries such as food and health care.
Our mission is to lead our customers to the achievement of significant growth in profitability through responsive use of Rapid Transformation Strategies. Working in a close partnership in which knowledge and experience are shared, we provide the means through which the members of your organization will collectively implement an improvement approach.
Please permit us to give you a detailed, personal explanation of the results we have produced while working with others... and those we can produce in partnership with you.
KKAI Lean Transformation Team
Your guide on a new path to productivity and profit.
When properly applied, the Lean approach drives business objectives faster, with more intensity, and with less risk. Success requires capturing improvements and driving bottom line financial metrics, as well as commitment, continuity, dedication and trust. Through our Enterprise Wide Lean Transformation system, a comprehensive conversion can be attained.
Follow these links to featured Lean Manufacturing expertise in:
Click on the button above to contact us and to request more information.
What You Can Expect
Sensei Approach
- We teach you the principles and application of lean as it relates to the specifics of your business.
- A typical client relationship involves an 18-30 month intense phase where week-long events are conducted at a monthly pace.
- Activities are supplemented with a combination of Value Stream Analysis, Assessments and Alignment reviews to ensure that the management team aligns its Lean Conversion with the Business Objectives
Consistency
Acting as a VP of operations to help lead your conversion, your Sensei works to develop your entire management team, providing:
- Staff Development
- P&L Impact
- Lean Accounting
- Lean Administration
- Change Management
- Product Development
- Supplier Development
- MRP to Flow Conversion
- On-Site Training
- Sustaining Improvements
- Problem Solving and Corrective Action
Enterprise Wide Conversion
The real value of the KKAI Lean Transformation Team business system is that we work with you in all aspects of your business, far exceeding simply "leading", to achieve enterprise wide transformation.
P&L Focused - Results Oriented
We start by understanding your business, after which we help you to define the objectives of Lean in your business. Once the goals have been established, we address:
- How to impact the key measures
- What to Value Stream Map
- Where to focus your Lean efforts to deliver results to the bottom line
In every case we look at the entire Value Stream to ensure each step taken will provide 'pay as you go' results.
How It Works
Our approach creates a model value stream in order to limit disruption and more rapidly bring about changes in method and culture. This includes:
Rapid Transformation Strategies
Rapid Transformation Strategies represent the most powerful competitive advantage for your organization. This process utilizes the Lean Transformation System and Kaizen Breakthrough Methodology to shrink time throughout the value stream, enabling improvements in quality, cost, delivery, safety, morale and lead time. By applying Rapid Transformation Strategies, achievement of three to five times industry growth can be attained.
Lean Transformation System
The Lean Transformation System is the proven method for reducing waste and production time, modeled on Toyota's renowned manufacturing process, Toyota Production System (TPS). Lean focuses on creating a continuous product flow and decreasing lead time. As a result, it dramatically accelerates time-to-market and new product development. Through Lean principles, you can attain exceptional results, such as:
- an increase of 25% to 40% in labor productivity
- a decrease of 40% to 50% in quality defects
- a 70% to 90% reduction in lead time
- a savings of 40% to 50% in floor space
- a decrease in inventory of 70% to 90%.
Kaizen Breakthrough Methodology
"Kaizen" is a Japanese word meaning "change for the better." The key concepts is that fundamental change and continuous improvement are essential. Kaizen focuses on creating cross-functional teams and a spirit of ownership among employees by empowering them to make changes. Together, our professionals and your employees study your processes and generate ideas for improvement. Through Kaizen, we help your company increase productivity, eliminate waste, and unite management and staff.
Lean Transformation Management
KKAI Lean Transformation Team consultants are highly experienced professionals with a minimum of ten years manufacturing, engineering and leadership experience. We take a hands-on, shirt-sleeved approach to partnering with your management team. Working side-by-side, we solve problems and implement solutions. Within days, you will see results in productivity, quality, and employee enthusiasm and commitment. Our success is based on our commitment to assuring complete customer satisfaction.
Implementation
Our goal is to incorporate new attitudes as well as new processes by building on your strengths. Employees at every level gain a refreshed outlook and a greater sensitivity for total corporate vision, mission and goals. Ours is a "people first" program to achieve rapid, continuous improvement. We help you instill a value of change and a willing attitude that quickly makes a difference in building new capabilities and capacity.
Creativity Before Capital
Our emphasis is on the optimum utilization of human capital. In every case, our pursuit of creative solutions has made a difference in long-term results. We locate the defining mark of your organization and use it to establish a new set of challenges leading to enhanced profit and productivity.
P&L Results
We achieve success together through immediate, quantifiable results. Benchmarks are determined in advance. Working as your partner, we help build improvements in your present position and practices. Importantly, employees at every level are encouraged to take ownership of goals and understand the incremental measurement of results.
Consistent With Your Vision
Our role is to build upon your strengths, ensuring that the goals achieved are consistent with your vision and culture.
Product Offering Options
Leadership Overview
KKAI Lean Transformation Team and your staff meet to explore the opportunity for a transformation partnership. This typically consists of a brief plant tour and summary of KKAI Lean Transformation Team's implementation methodology, followed by an open discussion of opportunities for your organization and next steps necessary to start the lean journey.
Organization Assessment
A 2-4 day on-site engagement with KKAI Lean Transformation Team and the site leadership to identify current status, to familiarize KKAI Lean Transformation Team with your business, and collectively develop an implementation strategy.
- Value Stream development
- Routing standardization of Products
- Operating Characteristics
- Business Plan/Strategic Plan Linkage
- Measurements
- Model Line/Value Stream
- Lean Progression Matrix
- Staff Lean rating
- Calendar of events
Organization Launch
A 2-3 day on-site engagement with KKAI Lean Transformation Team and the site Leadership to perform Value Stream Analysis on 80/20 of the enterprise/plant. Establish metrics and alignment of actions through Policy Deployment to drive financial results
Kaizen Breakthrough Event
A five day activity consisting of a KKAI Lean Transformation Team consultant and a cross-functional team with defined scope and objectives, focused on radically changing how a part the model value stream operates and performs.
- Objectives linked to financial performance
- Hands-on empowerment to make change
- Creativity before capital
- Utilizes organizations human capital
- Results linked to Value Stream and Policy Deployment with 60 to 90 day pay back
Transformation Strategy and System Tools
Organization Transformation Leadership
- Strategic Planning
- Organization Policy Deployment
- Value Stream Mapping and Management
- Demand
- Development
- Delivery
- Support and Administration
- Financial Measurement/Linkage/Behavior
- Abnormality Management at all levels
- Lean Daily Management I
- Lean Daily Management II
- Planning, Review, and Partnership Session
Lean Tools
- 5's
- Visual Management
- Routing Standardization
- Setup Reduction
- Assembly Flow and Design
- TPM and Autonomous Maintenance
- Jidoka Methods
- Schedule Systems
- Pull Systems
- Quality I
- Quality II
- Six Sigma
Other Lean Seminars and Training
Find out how the following Lean Instructional opportunities can benefit your organization.
- Lean Experience - 5-day class, normally open enrollment. Private sessions available for 30 - 42 people.
- Lean Leadership and Lean Value Stream classes - Both classes offered as 2-day programs, open enrollment.
- Private sessions available for 25-30 people.
- Kaizen Workshops - A 5-day facilitated process to improve both the efficiency and effectiveness of a process; applies to both manufacturing and administrative processes. In addition to the 5-day workshop, there is one planning day 4-6 weeks in advance.
- Value Stream Mapping Workshop - A 2-day facilitated process designed to view the entire factory or enterprise at the 35,000 foot level. A very popular tool used to plan a long term lean improvement strategy.
- Learning Laboratory - This process is designed to create improvement and to learn lean tools. It is both a unique and valuable service.
- Lean Assessment - This assessment is often done up front and inspects the Operations, Culture and Leadership of an organization. Often done in 1-2 days, after which a thorough, written report is presented. Additionaly, a Lean Transformation Plan is created based on the results of the assessment.
- Lean Training Development and Delivery - Ranging from a short overview to a 25-day program for experts, this option can be conducted independently or in collaboration with the client.
- Lean Coaching - General lean coaching can also be provided at a daily rate.
To find KKAI Consultants, Engineers and Experts with related expertise, enter your search query (type of expertise you are seeking) in the box below, choose to search the entire Rapid-Response site or just resumes, then click the search button. Please note that the list of resumes available online is a select subset of our vast database. If your search of our site does not reveal the expertise you are seeking, please call us toll-free (in the U.S.) at 1-800-367-5524 or contact us for more information and we will gladly assist you in locating the specific expertise you require.
Have an urgent engineering or scientific need that requires expert testimony, failure analysis or engineering consulting? Contact KKAI now for rapid response from a world-class expert.
1-800-FOR-KKAI (1-800-367-5524)
info@kkai.com