Lean Production
Client Testimonials
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PCI Pharma Services
PCI engaged VIPGroup for improvement projects (4 phases over 1.5 years) in Leadership Coaching during Transition, Inventory Process Assessment and Redesign, and Planning/Scheduling Process Improvement for a site that had experienced approximately 50% growth over two years. Leadership Coaching during Transition: VIPGroup provided leadership coaching and guidance for our Customer Facing Teams as we transitioned from a functional to customer centric structure. All desired goals were achieved resulting in a customer facing structure with appropriate KPIs and operating rhythm implemented. Inventory Process Assessment and Redesign: VIPGroup created and facilitated a PCI led team that analyzed our existing procurement processes and inventory management The project team recommended appropriate process improvements that are resulting in inventory reduction while ensuring component availability on time for operational conversion. The team continues to operate and is implementing organization structure changes expected to result is significant inventory and obsolescence write-off reduction. Planning/Scheduling Process Improvement: Created by the significant business growth, the existing planning and scheduling processes were ineffective causing operational scheduling changes on a daily basis and inability to adhere to schedules. The result was an increasing backlog of orders and difficulty achieving customer delivery expectations. VIPGroup created and facilitated a PCI led team that designed and implemented a “fixed schedule” planning and scheduling process using existing technology. As a result, backlog has been eliminated and schedule adherence and delivery performance are improving. In addition, site overtime costs driven by the order backlog has seen significant reduction. Bill Bolding COO, PCI Avery Dennison
"Over the last 2 years, I have utilized the Lean Business Simulation© as a training and development tool in two divisions to dozens of employees. It is an interactive, dynamic method for working with employees who may not have the benefit of external exposure to world class practices, bench marking other businesses and processes, or simply reading what's new in our global and competitive world. The exciting thing about the workshop is every employee at any level can be involved and the messages become clear to all, everyone can fulfill a critical role in the order-to-delivery cycle and it becomes "real life" before their eyes; how much we are capable of improving, how customer expectations are ever increasing, and our role in keeping them satisfied. This simulation is a powerful tool that demonstrates commitment to the customer, continuous improvement as a "given", and can support other business objectives by increasing employee involvement". Ellen Andre Plant Manager, Specialty Products Avery Dennison Trinity Rail Group
"You know, my phone rings a lot less and has been for some time with many fewer launch issues. I can attributed this to VIPGroup’s robust, professional Program Management activity. I see the results in that I have much less mitigation and referee type issues nowadays." Richard Seiner Vice President Operations Trinity Rail Group Underwriters Laboratories Inc
"You guys will be missed. I really appreciate the objective insight that Larry, Bob and the VIPGroup team provided to me and my management team. You were not only able to analyze and give feedback on the process, but also provide candid feedback on leadership improvements that were needed to accelerate improvements. You guys played a critical role in the success of our ULSFM©. Thank you." Jerald J. Stricker Vice President - North America Operations - Fire, Security & Signaling, HazLoc, Gas & Oil, Auto, Renewable Energy, Personal Flotation Devices, and Personal Protective Equipment Underwriters Laboratories Inc. Graphic Packaging Corporation
"Personally, I think the Lean Business Simulation© Training is one of the most effective methods I have participated in that makes a difficult concept easy to understand, and fun to learn. The whole process to team-based continuous improvement and learning is constantly reinforced in the day-long exercise. Sometimes it is difficult for office and floor associates to see how their work impacts meeting customer needs, but this training really brings to light the issues and the "ahas" in our process. Most people can relate to value-adding and non-value adding, but have a difficult time seeing their role in fixing the issues. Our experience has been that it is a very successful way to kick-off a major change initiative and getting folks thinking differently about their roles and their work. A powerful, yet simple tool that works well." David W. Scheible CEO Graphic Packaging Corporation "We implemented all their suggestions on flow improvements and layout. Their methodology was sound and we learned how to make the changes sustainable through changes to our culture and measurement system."
Vice President of Operations, $2B chemical, paints and stains manufacturer with retail operations worldwide. "VIPGroup provided us with an enlightening assessment of our operations detailing a business case for change with a good implementation plan. They really got our staff enthused and involved in change through their Lean Business Simulation© and then helped us implement the recommended changes on flow improvements, 5S and SMED. Their training and facilitation services were spot on."
Plant Director, $120M division of a $4.5B capital equipment manufacturer with worldwide operations. |
Underwriters Laboratories Inc.
Shortly after taking on the role of CEO of Underwriters Laboratories (UL), I became convinced that Lean would be a tremendous benefit to our business, our people and, most importantly, our customers. For the most part, Lean was a completely new concept to the deeply-rooted and established operations of our 100+ year-old company. Introducing the basic concepts of Lean and effectively integrating Lean into UL’s culture was of utmost importance. For help, I engaged the VIPGroup. (I had previously worked with Pat Lucansky and Bob Burke while at Medtronic and found them to be true Lean experts who deliver on time and on budget.) The VIPGroup, with their trained, seasoned Lean professionals, worked quickly to understand our company culture and how best to introduce Lean to the organization. Working closely with our internal team, the VIPGroup began introducing Lean concepts to all levels of the organization. The Lean solutions, coaching, mentoring and training, i.e. VIPGroup’s Lean Sigma Business Simulation©, they provided exceeded my expectations. They worked quickly to help us identify key issues we were facing and apply Lean with outstanding results. They also designed and implemented a new Lean tool that allows us to increase our operational visibility, profitability and horizontal teamwork. Their world-class Lean System For Managing© has been a tremendous success at UL. Pat Lucansky, Larry Bauman, Robert Miller, Willie Carter, Berry Metzger and the rest of VIPGroup are a team of professionals who working with your team, can design and implement tailor-made solutions and deliver on their promises. I would recommend the VIPGroup to those organizations looking for assistance in designing, implementing and auditing a Lean, Lean Sigma, or LSFM© program. Thanks to the VIPGroup team, Underwriters Laboratories is further down the Lean path and closer to achieving our vision than if we had tried to do this by ourselves. Keith Williams CEO Underwriters Laboratories Inc. Busch LLC
The VIP Group provided us with a detailed assessment of our major inside sales processes. They identified two major processes for efficiency improvement. Their consultants helped us set the foundation for change and removal of departmental silos. Their “hands on” approach was non-disruptive. They worked with all levels of our inside sales team to educate and develop the team’s continuous improvement skills. The VIP Group participated in the implementation of two new processes which have yielded significant efficiency gains. I would recommend the VIP Group and would use them again for future needs. Pete Kardok National Sales Manager Busch LLC Trinity Marine Products, Inc.
I am writing in reference to the consulting service VIP Group provided to my manufacturing business. Your skill at customizing lean to match the needs of the business and your group's ability to fit in with my team resulted in a successful implementation. We have already seen a positive return from this engagement. I have dealt with many consultants and VIPGroup is at the top of the list. I look forward to working with you again soon. Paul E. Mauer President Trinity Marine Products, Inc. TRINITY INDUSTRIES, INC. Huhtamaki
"Lean Business Simulation© is a great session for anyone who is planning to go from a random batch way of manufacturing a product to a more streamlined process. When you get the chance to brainstorm with your fellow employees and you really see how these changes benefit all parties - the employees, the shareholders (lower costs, quicker turnover in your product & quality improvement) and your very satisfied customer - it's great! What is important to keep in mind when you go back to your "real world work" these changes take time, input from employees is important and in the end, everyone is happier with the way things work." Anna Koltonuk HR Manager Huhtamaki Advanced Sterilization Products
"When teaching any idea to a group of individuals, it is always a challenge to combine the concepts of the material with the desire to learn effectively. The Lean Business Simulation© exercise does an outstanding job of effectively presenting the concepts, ideas, and metrics with a learning medium of active participation. The groups learn quickly what changes are needed to evolve from a Push system to a Pull system and how these improvements translate into bottom -line savings for the organization. I have used this session with both Suppliers and employees and the most important outcome is that we are now better aligned with ourselves and our suppliers. We all have a common vision of what is needed and this workshop is a good tool in telling us how to reach our goals." Scott Haase Group Manager, Procurement Advanced Sterilization Products (A J&J Company) "We had a compliance problem and did not know it until VIPGroup provided us with a detailed analysis of our department. WOW, what an eye opener. Their suggestions and technical knowledge in drug safety was superb and we implemented the entire approach we developed with them. They really do create a partnership. That was 10 years ago. We are still lean and have handled growth without adding staff."
Department Director, $8.9 B chemical, bio-tech, pharmaceutical firm with global operations. |
