Lean Six Sigma

In Focus

Culture Change is needed to achieve Lean

Lean and Culture

It is the alignment of culture which enables Lean to be internalized and successfully sustained by the organization

  • Lean Six Sigma Services Overview

    Improve quality while eliminating waste

    A staple of world-class companies, Lean and Six Sigma has accelerated in recent years to transform business in every industry.

    With foundations in the manufacturing industry, to improve quality and efficiency, Lean Six Sigma continues to be adopted globally by a host of companies and industries, but with mixed results.

    Lean Six Sigma is the combination of two philosophies: Lean Manufacturing, which eliminates waste, and Six Sigma, which improves maturity, quality and predictability in execution. Together they can help companies realize their full potential, transforming their performance – faster, cheaper, better. Despite its growing popularity and impressive results, Lean Six Sigma often fails to deliver expected results. A recent survey found that 65% failed to achieve expected value, and 44% failed to gain any competitive advantage.

  • WGA’s Lean Six Sigma Service Offerings

    Our experience across industries and geographies has revealed that when companies fail to sustain lean and/or six sigma programs, the root cause is traditionally “company culture.” Many companies do not incorporate the organizational change aspect needed to deliver the enduring benefits of Lean Six Sigma. As a result of our experience, WGA has developed an upfront change assessment that enables companies to address these cultural change issues and to identify which opportunities will have the quickest results with the least amount of resistance.

    Next, we plan a strategy to address the cultural issues in parallel while we identify the enterprise value streams, and then rapidly map out processes and costs. We then conduct a bottleneck, waste and quality analysis. Finally, we zero in on areas for improvement, conduct training, optimize improvement and execute changes.

    Lean Process

    Operations streamlining

    • Kaizen
    • Process waste and bottleneck elimination
    • Competency building
    • Key Performance Indicators (KPI)
    • Visual Operations
    • 5S, 6S and 7S deployment
    • Layout/flow optimization
    • Cell/line process improvement
    • Logistics/inventory optimization
    • Yield/quality improvement
    • Utilization improvement
    • Value stream mapping
    • Business process management
    • Industry benchmarking
    • Lean Culture Deployment
    • Operational Excellence
    • Workforce right sizing
    • Lean administration and support functions
    • Outsourcing/in-sourcing
    • Leadership development
    • Simplifying Complexity
  • Lean Six Sigma Case Studies

    Lean on me: Achieving Lean Sustainment through Culture Change

    Lean on me: Achieving Lean Sustainment through Culture Change

    Culture Change is needed to achieve Lean. It is the alignment of culture which enables Lean to be internalized and successfully sustained by the organization

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    Standards: Standard work is a key element of high-performing, consistent, and predictable operations. Focus on the critical few, those in greatest need of improvement

    Standards: Unlock standards and implement change that matters

    Standards: Standard work is a key element of high-performing, consistent, and predictable operations. Focus on the critical few, those in greatest need of improvement

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    Overall Equipment Effectiveness (OEE): The perils of pervasive poor performance. Developing an impactful and enduring manufacturing operations recovery strategy through OEE Segmentation

    OEE: The perils of pervasive poor performance

    OEE Overall Equipment Effectiveness. Developing an impactful and enduring manufacturing operations recovery strategy through OEE Segmentation.

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    Lean

    Lean – The Fragility of Kaizen

    Lean | The pitfalls of Kaizen, a culture seeking “constant improvement” at all costs results in fragility and unintended consequences

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    Insight: The Rise of Lean And Why It Matters

    Understanding the business value of lean and how world-class organizations are unlocking the benefits of lean and why it matters.

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  • $276B Global Pharma, Consumer and Medical Device Manufacturer
    Jose
    General Manager

    Supply Chain Operations

    “After a number of global product recalls, front-page news, U.S. Senate hearings and a FDA Consent Decree, we began to make sweeping improvements across our network of manufacturing sites. We engaged WGA to develop a strategy and manage efforts. I repeatedly call on WGA’s world-class team to assist our organization with strategy, planning and critical initiatives.”

    $102B Pharmaceutical Manufacturer
    Tom
    Sr. Director

    Manufacturing Operations

    “WGA assisted us with developing and executing scenario-based turnaround strategies and addressing a number of business problems. WGA’s experience and services have helped us reduce operational costs, increase our competitiveness and improve operations.”

    $2.5B Food Manufacturer
    “After a number of setbacks with a large multi-year Business Transformation, we engaged WGA to assess our deployment model, PMO and user adoption problems. WGA helped us identify a number of corrective actions and deployed an innovative organizational change management strategy and practical methods that got us back on track. “
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