Lean/Six Sigma at Omnex

Today's Challenge

You need to make price reductions, create better quality, and deliver with shorter lead-times. Clearly you need a proven method for achieving this throughout your company on a rapid, systemic and continuous basis. Lean and Six Sigma can result in the kinds of changes you're looking for.

Value Proposition

Lean/Six Sigma (LSS) deployment is a companywide strategy to achieve breakthroughs in areas such as productivity improvement, PPM reduction, lead time and cycle time reduction. Properly implemented, Lean improvement methodology improves on-time delivery while freeing up capital and reducing the cost of poor process flow (COPF) by 75% to 90%. The Six Sigma quality improvement enhances customer satisfaction while reducing the COPQ from 20% of total sales revenue to 10% or less. Other competitive advantages include delivering products in 50% to 80% less time and reducing manufacturing and overhead costs by 20%.

Omnex's Approach

Omnex is a pioneer in the project-based approach to integrated Lean/Six Sigma. Companies disillusioned with the traditional (and sometimes costly) training based approaches now focus on the development and implementation of systemic, project-based approaches to achieving sustained, state-of-the art operations excellence. This approach has two major advantages: your investment in training is captured when the project is completed, and the participants learn how to successfully manage a project while linking events and activities. This results in substantial saving while people are still in training.

Initial Engagement

Our approach begins with an engagement that includes an on-site assessment and data gathering followed by a planning workshop with your management team. The intent would be to have those responsible for leading and managing the continuous improvement projects become Black Belt candidates working in project teams. Each team would be comprised of a Champion (the Process Owner) and up to four Black Belt candidates. The Black Belt training is intended to work on real projects achieving real results.

The participants will produce project logs and project plans for achieving improvements. They will create product, process and project scorecards to link each improvement project to bottom-line results. When this is completed, the top management team will have a roll-out plan identifying the critical improvement projects specific to each process, and an estimated cost savings of future state goals for each process.

Lean/Six Sigma Implementation Roadmap

Whether the focus is on Lean, Six Sigma, or Lean/Six Sigma, an implementation project typically takes between six and twelve months. The actual time will depend on many factors, but the project-based workshops approach will allow your team to immediately apply lessons learned so you can achieve savings quickly. This approach provides the ultimate in value, cost savings and profitability. At the conclusion of the engagement, the team will learn how to successfully link all activities and events together while being able to replicate and sustain future projects.

Establishing Expectations and Sustaining Successful Projects

The real success of a Lean/Six Sigma program is measured by the sustainability of the program. To ensure sustainability of your Lean/Six Sigma program:

Qualifications

All Omnex consultants in this program are certified Six Sigma Black Belts with also many years of experience in developing Lean Manufacturing programs for Fortune 500 companies.