The LEAN Factory Audit is for manufacturing, operating and logistics companies, processing physical items or turning them into higher value goods.

Manufacturing Process Matrix

The factory audit is suitable for all five manufacturing configurations:

  • Projects (X): producing one of a kind in flexible line flow, such as construction, building a pipeline or engineering a spacecraft,

  • Job Shop (A): processing similar jobs in jumbled flow, such as print shop, tooling shop, repair shop, custom furniture work shop,

  • Flow Shop (B): processing batches in disconnected line flow, such as producing bread, shoes, garment, medical devices,

  • Line Flow (C): repetitive manufacturing in connected line flow, such as assembly of computers, cars, tires, toys,

  • Continuous Flow (D): uninterrupted production of a single product, such as cement, steel, beer, paper, oil.

Twenty keys to Wolrd-Class Manufacturing

  1. Costing and budgeting, process and system

  2. Efficiency management and resource planning

  3. Inventory amount and management system

  4. Layout, distances, communication, and ergonomics

  5. Leadership and policy deployment process

  6. Maintenance and assets management

  7. Management, priority setting, decision making

  8. Metrics and performance measurement

  9. Quality level, process capability, yield

  10. Readiness, willingness to change, flexibility

  11. Renewal, innovation, and improvement

  12. Service level, internal and external customers

  13. Solving, root-cause analysis and elimination

  14. Standards, policies, procedures, and instructions

  15. Structure, organization, and housekeeping, 5S

  16. Teamwork cooperation and coordination

  17. Technology, equipment, computers, and systems

  18. Time management, deadlines, and commitments

  19. Training, capability building, skill flexibility

  20. Visuals, status signals, visual management

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