LMOS - Lean Manufacturing Operating System

Our Lean Manufacturing Operating System (LMOS) is very comprehensive and includes a framework of six interdependent elements. Our implementation process recognizes these lean elements and connects them to drive flow manufacturing.

The Six Interdependent Elements:

  1. Flow Manufacturing - Flow is how work progresses through the production system. LMOS pulls material through a production system matching customer demand to ensure no interruptions to the customer.


    • Site Planning

    • Value Stream Mapping

    • Gap Assessment

    • Organized by Value Streams

    • Total Product Cycle Time

    • Takt Time

    • Flow Improvement

    • Process Synchronization

  2. Material Movement - Material needs to flow or move through the manufacturing operations in harmony with the entire system. LMOS takes into account the entire value stream starting with customers down to the suppliers.


    • Shipping to Schedule

    • Building to Plan

    • Plan for Every Part

    • Designated Storage

    • Container Right Sizing

    • Pull Systems

    • Internal Delivery Routes

    • External Material Delivery

  3. Operational Availability - The full utilization of team members, material and machine to meet customer demand.


    • Understanding and Continuous Improvement

    • Production Reporting

    • Quick Response System

    • Planned Maintenance System

    • Owner Operator

    • Spare Parts

    • Quick Setup

  4. Quality System - Consists of operating practices focused to consistently exceed customer requirements and expectations. Quality Systems formalize processes, specifications and responsibilities, taking into account people, material and equipment.


    • Quality Leadership

    • Quality System Requirements

    • Protect the Customer

    • Measurement System Analysis

    • Process Capability

    • Inspection and Test

    • Detect Solve and Prevent Quality Problems

    • Measurement and Feedback

  5. Workplace Organization - Uses visual management communication tools that bring together the flow of information and product. Visual communications can readily show that standard practices are being followed.


    • Workplace Organization / 5S Program

    • Visual Controls

    • Address System

    • Parts Presentation

    • Plant Communications Center

    • Area Information Center

  6. Employee Environment and Involvement - All people within an organization working as a team to continuously improve and accomplish common goals.


    • Beliefs and Values

    • Communications Plan

    • Health and Safety Program

    • Education and Training

    • Cross Functional Training

    • Recognition System

    • Suggestion System

    • Natural Work Groups

LMOS applies these six elements in harmony throughout the total system. The structure is necessary to identify and eliminate waste and provides a solid foundation for Manufacturing Excellence.

The tangible results:

  • Improved Operational Efficiency

  • Decreased Operational Expenses

  • Decreased Employee Turnover

  • Improved Asset Utilization

  • Reduced Cycle Times

  • Improved First-Time-Quality

  • Reduced Inventory

  • Improved Delivery Performance