Lean transformation engagements remove non-value-add waste from an entire value stream, not just one process, using value stream mapping, 5S, and pull-based flow redesign.
Overview
Where a process improvement project fixes one process, a Lean transformation looks at the whole value stream, from order to delivery, or from patient intake to discharge, and removes the waste hiding in the handoffs between steps.
We use value stream mapping to make the current state visible first, because most waste is invisible until it's drawn on a wall.
Lean tools work alongside Six Sigma statistics rather than instead of them, a value stream map tells you where to look; DMAIC tells you why a specific step is failing and how to prove the fix holds.
Who it's for
- Manufacturing, warehouse or service operations with long lead times relative to actual work content
- Organizations planning a facility or process redesign
- Leadership teams ready to commit to a multi-month improvement program, not a one-off workshop
Consultations, workshops and working sessions are available in English, Hindi, Hinglish.
Led by Master Black Belt-level Six Sigma consultants. India · United States · United Kingdom.
Our approach: steps & schedule
1Current-state mapping
- Value stream map of the end-to-end process
- Identify the eight wastes (DOWNTIME)
2Future-state design
- Design the target flow
- Identify pull systems and kanban opportunities
3Kaizen implementation
- Run focused Kaizen events on priority waste
- 5S and visual management rollout
4Sustain
- Leader standard work
- Visual metrics boards and daily management
Deliverables
- Current-state and future-state value stream maps
- Prioritized waste-elimination roadmap
- Kaizen event outcomes and standard work documents
- Visual management system for daily operations
Outcomes
- Reduced lead time across the value stream
- Lower inventory and work-in-process
- A visible, sustained daily management system
Engagement model
Typically a 3–6 month program run in Kaizen sprints. Pricing is quoted after a scoping call, based on program length and team size.
Applied in these industries
Related training
What clients say
“Anurag sir has a good experience and knows how to explain things with good examples that we can relate to from our daily life. It was a really wonderful session of Six Sigma BB+AI Training.”
“Great learning experience with Anurag Sir. His teaching style is very practical and easy to understand. He explains Six Sigma concepts with real-world examples, which makes the sessions very interesting and useful.”
“The Quality Management Trainer Mr Anurag Jain program was conducted very well. The sessions were clear, practical, and highly informative. It enhanced our understanding of quality standards and real-time implementation.”
Frequently asked questions
Is Lean transformation only for factories?
No, we've applied value stream mapping to warehouses, hospital wards, and back-office loan processing. Any repeatable, multi-step process with handoffs can be Lean-mapped.
How much does a Lean transformation program cost?
Pricing is quoted after a scoping call, based on program length (typically 3–6 months) and team size. Ask us for a quote once we've scoped your value stream.
Who from your side runs the program?
A Lean Six Sigma Master Black Belt-level consultant leads the value stream mapping and Kaizen facilitation, working directly with your leadership and shop-floor/process teams throughout.
What does our team need to commit?
Leadership sponsorship for the full program length, not a one-off workshop, plus operator time during Kaizen events. Lean transformation is a multi-month commitment, we're explicit about that upfront.
How are results measured?
Against the current-state value stream map's baseline lead time, inventory and work-in-process figures, compared to the future-state design once implemented.
What happens after the program ends?
You keep the visual management system, leader standard work documents, and a trained internal team to run daily management going forward, the goal is a system that sustains itself after we leave.