Embed a Lean Manufacturing Culture

Leanbiz Consulting is uniquely positioned to lead you on your path toward world class operational efficiencies and reap the rewards of an engaged and productive workforce.

We have a deep understanding of operations and a strong track record of delivering successful and transformative Lean Programmes that create lasting value. Our programmes are tailored to the South African manufacturing environment where we have simple programmes that deliver high value by leveraging on your entire workforce. Let our experienced and dedicated team of Industrial Engineers, led by a Black Belt, coach your teams to success and institutionalize a high-performance culture of continuous improvement.

Over the years, we have developed unique cloud-based software LiveFactory that embed Lean manufacturing best practises directly into your Supply Chain processes. We are passionate about creating a responsive manufacturing environment where abnormalities are highlighted and responded to with unmatched transparency. LiveFactory and QuantumLeap implemented together, help our customers achieve world-class operational performance.

Our 5 Step Process

  1. Executive alignment sessions defines the lean programme structure and breaks it down into simple step-by-step divisional goals and objectives

  2. Create a responsive visual work environment using LiveFactory which provides the visual monitoring system for your teams. The system highlights abnormalities, promotes just-in-time and provides the analysis to drive focused Kaizens.

  3. Change mindsets through interactive training sessions and Gemba walks. Learn the common language of Lean and how to conduct Kaizens under our expert guidance and mentorship.

  4. Kaizen improvement activities focus on specific problem statements prioritized by our proven programme. This improves manufacturing processes, strengthens systems and drives shop floor efficiencies where it will have the greatest impact on your bottom-line.

  5. White Belt Training and Certification ensures that you capacitate each division with sufficient change agents who can perform Kaizens and entrench the culture of continuous improvement.The journey often yields significant unexpected benefits as inefficiencies are uncovered. As we get further into the programme, communication across the company improves and a new way of collaborative working emerges. Over time, teams start to use the tools independently to solve problems in their areas of responsibility.

QuantumLeap White Belt Certification

Having certified White Belt employees distributed across a company really helps entrench the principles of Lean and embed the culture of continuous improvement.

Our White Belt Training program teaches your employees the fundamental concepts of Lean manufacturing in an easy-to-understand and structured methodology.

Almost half the course is dedicated to teaching your employees exactly how to perform Kaizen improvement projects.

We believe that this course is a real investment to the business as these employees will have the framework and understanding to perform improvement projects on an on-going basis.

  • Over 2hrs of Online Training Videos provided by a black belt. These are broken into 15 to 20min Videos. We’ve found that short format videos make it easier for employees to digest key concepts and it’s more flexible in terms of options to provide employees with study time.

  • A ring-bound course handout is provided to each candidate

  • Entry to the White Belt Exam which is written as a group on your site. The pass mark is 75%. Over 90% typically pass on their first attempt.

  • A Kaizen also has to be successfully led by the candidate through to completion.

  • On certification, a White Belt Course Certificate is provided per graduate to the company.

Total Kaizens

401

White Belts Certified

55

Testimonials

— Raeesa Osman, CoMED Production Manager —

My experience thus far has been phenomenal.   My team and I were briefly introduced to lean previously and we have worked on many kaizen related  activities but not to the extent that we are doing now.  When we announced that Comed will be re-embarking on the lean journey with Salim there was quite a bit of negativity from my production teams because they felt that they have done this several times and there has not been any change and equipment is our biggest problem. After much motivation and  reinforcement I managed to get the buy-in from my personnel. Also I encouraged ‘’ BIG COMPANY THINKING ‘’ and investing  in your future. As a  manager I adopted Change as Culture and thus transformed my team to accept change.

Since the buy-in of our personnel, the various projects that we have worked on,  as well as the various interactions and coaching from Salim, we have momentum like never before. We have greater direction now. We have personnel who were initially introduced to Lean and it’s problem solving tools and gradually more and more people are participating.

Salim’s coaching style and practical examples really gets across the principles of lean and enabled my employees who were once fixed in their conventional routines to go back their shop floor ‘GEMBA’ with confidence to make a difference.

As a manager leading a multifaceted team, I have seen amazing improvements  in productivity  and efficiencies. There is so much more focus from my teams. All employees are focused on delivering value. Everyone communicates in the same language. The greatest win by far is creating an environment of shared leadership and the ability for flexible thinking. I am extremely proud of our achievements thus far and look forward to learning new tools and all the changes that are yet to come!

— Sharon Sithole, CoMED Production Supervisor —

My experience with lean/kaizen course has been fun, interesting and a major learning curve. It has completely empowered me to see things in a different view both in the workplace and outside the workplace. It has given me the opportunity to see change in a positive way.

SkyView has greatly improved communication amongst departments and improved relationships in the company.

LiveFactory has been a great motivation for me because it has brought us together as a production team to challenge ourselves to perform at our best and improve our OEEs at all times.