Lean 4.0
Over the last 15 years, KIAP has developed and refined its own customized approach to operational transformation, leading to significant performance improvement in manufacturing organizations.
With the current rapid changes in manufacturing technology and information systems, there is a huge scope to complement lean implementation with a judicious deployment of Industrial Internet of Things(IIOT) solutions to multiply the business benefits in terms of improved productivity and OEE, throughput time and inventory reduction, enhancing quality and reducing costs. These solutions also enable ease of monitoring and tracking relevant process and performance parameters, ensure data sanctity for right decision making and error proof critical areas thereby avoiding catastrophic process and delivery failures. Studies show that,
“When either approach, Lean or IOT applied alone, it can reduce conversion cost by 15%,whereas the integrated partnership approach reduces conversion cost by 40%, Cost of Poor Quality(COPQ) by 20% and Work in Process (WIP) by 30%”
It therefore makes sense to seamlessly merge the Lean philosophy with Industry 4.0 and we call this integrated approach Lean 4.0.
IOT solutions can be deployed at each phase of a typical lean implementation cycle as we can see from this diagram. The callouts show IOT interventions typical of each implementation phase.
Our Approach
Over the last 15 years, KIAP has developed and refined its own customized approach to operational transformation, leading to significant performance improvement in manufacturing organizations. However studies show that,
“When either approach, Lean or IOT applied alone, it can reduce conversion cost by 15%,whereas the integrated partnership approach reduces conversion cost by 40%, Cost of Poor Quality(COPQ) by 20% and Work in Process (WIP) by 30%”
It therefore makes sense to seamlessly merge the existing consulting approach with the new technological advancements to multiply value to businesses. The diagram below shows our well defined consulting as well as typical IIOT solutions currently offered by technology providers that synergize at specific points in the cycle.
Design
- Make a technology / Low Cost Automation plan while making the Lean roadmap
Prepare
- Data needed for improvement projects can be related to machines / lines / materials
- Appropriate devices for computing OEE / line stops / rejections can be introduced at this stage
Improve
- LCA for improvements such as Jidoka (line stop), error proofing to avoid defects
- Analysis and alerts for line stops, bottleneck identification, deviations
- Monitoring and deviation alerts for process, machine conditions
- Material flow – kitting, pull based WIP management can all be electronically done
Standardize
- Validating the results of improvements made requires continuous monitoring of data
- Electronic SOPs both for display as well as guidance, also for deviation monitoring
Sustain
- Various OPEX assessment checklists and scores can be digitized and visually displayed
- Monitoring can help in continual improvement journey as data is now readily available for next round of diagnosis
Frequently Asked Questions(FAQs)
Q. What services does Kiap offer?
- Kiap provides a comprehensive range of business consultancy services, including strategic planning, financial advisory, market analysis, operational efficiency, and digital transformation. We tailor our services to meet the unique needs of each client.
Q. What services does Kiap offer?
- Kiap provides a comprehensive range of business consultancy services, including strategic planning, financial advisory, market analysis.
Q. What industries does Kiap specialize in?
- Kiap has experience working across a diverse range of industries, including technology, healthcare, finance, manufacturing, and retail. Our consultants bring industry-specific knowledge to help you navigate challenges and seize opportunities in your sector.
Q. How does Kiap approach consulting projects?
- We start with a thorough assessment of your business to understand your challenges and objectives. Based on this, we develop a customised strategy and work closely with your team to implement solutions, monitor progress, and ensure sustainable growth.
Q. How can I get started with Kiap?
- To get started, you can contact us through our website or call our office to schedule an initial consultation. We’ll discuss your needs and explore how Kiap can assist your business.
Q. What sets Kiap apart from other consultancy firms?
- Kiap distinguishes itself through a client-focused approach, deep industry expertise, and a commitment to delivering measurable results. We prioritize building long-term relationships and providing value beyond the project scope.
Q. Does Kiap offer support after the consulting project is completed?
- Yes, Kiap offers ongoing support to ensure that the strategies and solutions implemented continue to deliver results. We provide follow-up consultations and can assist with any adjustments or additional needs that arise.
Q. How does Kiap ensure confidentiality and data security?
- We take confidentiality and data security very seriously. Kiap adheres to strict protocols to protect your sensitive information, including secure data handling practices and confidentiality agreements.
Q. What is the cost of Kiap’s services?
- The cost of our services varies depending on the scope and complexity of the project. During the initial consultation, we’ll provide a detailed proposal outlining the costs associated with your specific needs.
Q. Can Kiap assist with international business expansion?
- Yes, Kiap has experience in helping businesses expand into international markets. We provide market entry strategies, regulatory guidance, and support in navigating the complexities of global operations.
BUSINESS EXCELLENCE
A uniquely designed Accelerated Business Transformation Workshop for Entrepreneurs and Family Managed Business Owners
OPERATIONAL EXCELLENCE
Operational Excellence manifests itself through integrated performance across revenue, cost, and risk.
LEAN INDUSTRY 4.0
KIAP is working with select technology partners who have developed robust solutions that complement our gemba implementation.
GUIDED STUDY TOURS
The study tours are conducted for post-graduate college students, family-managed business students, and business houses.
MASTER TRAINING PROGRAM
KIAP focuses on improving the financial structure of a company to improve its financial stability and operational efficiency.
FINANCIAL STRUCTURING
KIAP focuses on improving the financial structure of a company to improve its financial stability and operational efficiency.
BUSINESS EXCELLENCE
A uniquely designed Accelerated Business Transformation Workshop for Entrepreneurs and Family Managed Business Owners
OPERATIONAL EXCELLENCE
Operational Excellence manifests itself through integrated performance across revenue, cost, and risk.
LEAN INDUSTRY 4.0
KIAP is working with select technology partners who have developed robust solutions that complement our gemba implementation.
GUIDED STUDY TOURS
The study tours are conducted for post-graduate college students, family-managed business students, and business houses.
MASTER TRAINING PROGRAM
KIAP focuses on improving the financial structure of a company to improve its financial stability and operational efficiency.
FINANCIAL STRUCTURING
KIAP focuses on improving the financial structure of a company to improve its financial stability and operational efficiency.
Featured Case Studies
Kiap Partners
Founder's Insights
KANZEN INSTITUTE ASIA-PACIFIC PRIVATE LIMITED
Dr. Shrinivas Gondhalekar, known as Dr. G, was a trailblazer in quality management in India. As the founder of Kiap in 1992, he introduced the concept of Kaizen from Japan to India after studying under Masaaki Imai, the father of Kaizen.
A PhD holder from IIT Mumbai and a PGDIE graduate from NITIE, Dr. G regularly led study tours to Japan, sharing insights from Japanese management practices. He mentored numerous PhD students, leaving a lasting educational legacy.
Dr. G’s book, Chronicles of a Quality Detective, reflects his deep expertise in quality management. His pioneering work continues to inspire excellence at Kiap and beyond.
Testimonials
Why Choose Us
Expertise You Can Trust
Customised Solutions
Results-Driven Approach
Client-Centric Philosophy
BUSINESS EXCELLENCE
A uniquely designed Accelerated Business Transformation Workshop for Entrepreneurs and Family Managed Business Owners
OPERATIONAL EXCELLENCE
Operational Excellence manifests itself through integrated performance across revenue, cost, and risk.
LEAN INDUSTRY 4.0
KIAP is working with select technology partners who have developed robust solutions that complement our gemba implementation.
GUIDED STUDY TOURS
The study tours are conducted for post-graduate college students, family-managed business students, and business houses.
MASTER TRAINING PROGRAM
KIAP focuses on improving the financial structure of a company to improve its financial stability and operational efficiency.
FINANCIAL STRUCTURING
KIAP focuses on improving the financial structure of a company to improve its financial stability and operational efficiency.
Featured Case Studies
