Campana Building Consultants

Lean Consulting and Business Engineering

At Campana Building Consultants we have developed a consulting area that specializes in helping clients improve performance and EBITDA in different industries. This area includes, streamlining of operations, facilities layout, standardization of products and internal procedures, as well as new product launches, cost reduction, and operational improvements including supply chain, logistics and finance. This area utilizes Lean Manufacturing, Six Sigma, Kaizen, 5S and Total Quality Management (TQM) techniques to achieve significant cost and time reductions and improve productivity.

Lean Manufacturing

Initiative focused on eliminating all waste in manufacturing processes. The Production System Design Laboratory (PSD), Massachusetts Institute of Technology, states that, “Lean production is aimed at the elimination of waste in every area of production including customer relations, product design, supplier networks and factory management. Its goal is to incorporate less human effort, less inventory, less time to develop products, and less space to become highly responsive to customer demand while producing top quality products in the most efficient and economical manner possible.”

Principles of Lean Enterprise:

  • Zero waiting time
  • Zero Inventory
  • Scheduling — internal customer pull instead of push system
  • Batch to Flow — cut batch sizes
  • Line Balancing
  • Cut actual process times

Six Sigma

At many organizations simply means a measure of quality that strives for near perfection. Six Sigma is a disciplined, data-driven approach and methodology for eliminating defects (driving toward six standard deviations between the mean and the nearest specification limit) in any process – from manufacturing to transactional and from product to service.

The statistical representation of Six Sigma describes quantitatively how a process is performing. To achieve Six Sigma, a process must not produce more than 3.4 defects per million opportunities. A Six Sigma defect is defined as anything outside of customer specifications.

Principles of Lean Enterprise:

  • Define
  • Measure
  • Analyze
  • Improve
  • Controls

Kaizen

Japanese term that means continuous improvement, taken from the words ‘Kai‘ that means continuous and ‘zen‘ that means improvement. Some translate ‘kai‘ to mean change and ‘zen‘ to mean good, or for the better. Kaizen is a philosophy of continuous improvement in which EVERYTHING can and must be improved. It is a process that engages the “human element” while eliminating all forms of non-value added activity and waste.

5S

Is one of the foundation concepts of lean. The Japanese originals were: Seiri, Seiton, Seiso, Seiketsu, Shetsuke. (Additional S’s such as Safety or Security are sometimes added.)

Principles of Lean Enterprise:

  • Sort
  • Set
  • Shine
  • Standardize
  • Sustain

Toyota Production System (TPS)

A production system which is steeped in the philosophy of "the complete elimination of all waste" imbuing all aspects of production in pursuit of the most efficient methods.

Total Quality Management (TQM)

This is a management approach that originated in the 1950s and has steadily become more popular since the early 1980s. Total quality is a description of the culture, attitude and organization of a company that strives to provide customers with products and services that satisfy their needs. The culture requires quality in all aspects of the company’s operations, with processes being done right the first time and defects and waste eradicated from operations.

To be successful implementing TQM, an organization must concentrate on the eight key elements:

Principles of Lean Enterprise:

  • Ethics
  • Integrity
  • Trust
  • Training
  • Teamwork
  • Leadership
  • Recognition
  • Communication