Get to know the LeanSigma Kaizen transformation

LeanSigma is the fusion of best practice methodologies - lean business culture that embraces LeanSigma Kaizen events and Six Sigma measurement and quality tools.

LeanSigma is the fusion of best practice methodologies - lean business culture that embraces LeanSigma Kaizen events and Six Sigma measurement and quality tools.

Joining the fast-paced Kaizen transformation with the process analysis of Six Sigma, TBM's LeanSigma represents the next generation of productivity improvement methodologies: rapidly deployed, sustainable change.

LeanSigma roots out inefficiencies to create a culture of continuous improvement, tracked by consistent measurements.

The transformation begins at the intuitive level, where trained operators and engineers are taught to look for waste and redundancies, and progresses to real time improvements.

The goal is to achieve productivity and growth that serve all constituents of the enterprise -- reducing both defects and lead-time.

The revolutionary element is the speed with which LeanSigma is applied to an organization.

Many companies see results in a week, as waste is quickly eliminated from the value stream.

The speed of LeanSigma comes from its foundation in Kaizen Breakthrough Methodology.

Kaizen Breakthrough is a cross-functional, team-based process for rapid improvement that focuses on a physical transformation.

"Kaizen," from the Japanese words for "change" and "good," is commonly translated as "change for the better," and seeks fast, practical solutions to everyday challenges.

Kaizen Breakthrough Methodology empowers employees by involving them in the decision-making process -- instilling lasting cultural change and sustainable results.

By implementing the LeanSigma Transformation, an organisation gives its employees the tools to move to new levels of excellence, building an improved enterprise through creativity not capital.

The LeanSigma Transformation: Eliminates waste.

Ensures that flow of products match market demand.

Develops highest quality at the lowest cost.

Re-designs processes to suit product volume.

Incorporates "managed creativity"-- a set of technical tools that through a team focus, design products and processes right the first time.

LeanSigma has repeatedly proven its success at developing streamlined processes to match production to demand at globally competitive prices.

Some of the companies using LeanSigma as a competitive advantage include: Maytag changed to LeanSigma( production in 1997 and has seen rapid significant improvement in productivity and quality, as well as waste elimination in their appliance factories.

One of Maytag's plants that adopted the principles of the LeanSigma( Transformation is making industry history, moving revenue-generating new products into the market alongside the company's more traditional product lines.

With Maytag's ongoing commitment to the LeanSigma( process, the company continues to make groundbreaking improvements.

Pella Corporation, a leading producer of premium windows and doors, adopted the LeanSigma Transformation in 1993, and has been rewarded with ongoing improvements in engineering and production.

By replacing its big equipment with smaller, smarter solutions, Pella realized a 50 percent reduction in operational lead-time and product development time.

The formation of employee teams and development of programs to identify and streamline key processes have helped Pella's sales more than double and profits increase five-fold since 1993.

Applica Consumer Products, a leading manufacturer, marketer and distributor of branded and private-label small electric consumer goods, was struggling financially in 1998 and labeled a "doubted going-concern" by analysts.

Applica's adoption of the LeanSigma Transformation has been an integral part in the success of the company's turnaround.

The process began on the factory floor, where improvements were immediately visible as the company trimmed waste and aligned production with demand.

In 2001, the company implemented LeanSigma into its service divisions.

Applica reduced forecast lead-time from 230 to 35 days and drastically reduced the gap between product production and appearance on retailers' shelves.

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