1. LEAN IMPLEMENTATION
PROPOSAL

2. ENABLING OPERATIONS TO ACHIEVE MORE WITH EXISTING
RESOURCES LEADING TO:
• Reduced Lead Time
• Increased productivity (minimum 20%)
• Increased Equipment Performance
• Less Rejects and rework and much more…..
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3. OBJECTIVES
• To move 80% of Lab staff who have limited Lean
culture to commitment level and be involved in
Lean projects
• To move 20% who have not yet attended any lean
training to be sufficiently motivated, to be trained
and involve in projects
• Achievement of relevant Departmental Critical
Success Indicators
• Help achieve 20% productivity improvement
• To turn Lab into Lean Model area
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4. LEAN CULTURALIZATION MODEL (6 months)
Lean Awareness Lean Innovation Lean Culture
Diagnostics & Planning
• Value Stream Mapping
• Lean maturity
Assessment
• Gap analysis for:
• Lean Implementation
• Lean Culture
• Skills & Training
• Identifying Improvement
opportunities and
turning Critical Success
Indicators into projects
• Communication and
setting up of Lean
Implementation
Structures & Metrics
Training & Projects Mentoring
• Training in necessary tools such as:
• Team Leadership tools
• Motivational tools
• Waste Reduction
• Kaizen methodology
• Quick Changeover
• Pokayoke
• Kanban & Inventory Management
• Bottleneck Management etc.
• Hands-On coaching on projects and
improvements
• Team Leadership Coaching and motivational
mentoring
• Handling resistance to change in projects
• Periodic Review by teams with management
team (weekly)
• Progress monitoring by consultant with teams
and management team
Culturalization
• Establishing
Standardized Lean
Practises and
Leadership roles &
Management
Involvement
• Establishing Lean
Continuous
Improvement Cycle
• Establishing Gemba
Meeting
• Addressing change
resistance and
motivational issues on
continuing Lean as a
culture
• Rewards &
Recognition
• Best Practice Sharing
ONE MONTH THREE TO FOUR MONTHS ONE MONTH
Support & Training is for a maximum of 80 persons 4

5. CONSULTANT LED PROJECT MODEL (2 months)
Lean Awareness Lean Innovation Lean Culture
Diagnostics & Planning
• Value Stream Mapping
• Lean maturity
Assessment
• Gap analysis for:
• Lean Implementation
• Lean Culture
• Skills & Training
• Identifying Improvement
opportunities and
turning Critical Success
Indicators
• Identify one critical
Lean Project towards
CSI achievement
• Plan project
requirements & support
team
Training & Projects Mentoring
• Hands-On project led by consultant and
improvement actions are implemented by
support team
• Handling resistance to change in projects
• Periodic Review by teams with management
team (weekly)
• Progress monitoring by consultant with teams
and management team
• Periodic Review by Department managers
• Training on Tools as OJT
•
Culturalization
• Establishing
Standardized work and
metrics for
sustainability of project
results
TWO WEEKS ONE MONTH TWO WEEKS
Support & Training is limited to project support team – estimated 20 persons
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6. HYBRID MODEL (3 months)
Lean Awareness Lean Innovation Lean Culture
Diagnostics & Planning
• Value Stream Mapping
• Lean maturity
Assessment
• Gap analysis for:
• Lean Implementation
• Lean Culture
• Skills & Training
• Identifying Improvement
opportunities and
turning Critical Success
Indicators
• Identify one to two
cross departmental
critical Lean Projects
towards CSI
achievement
• Plan project
requirements & identify
team members
Training & Projects Mentoring
• Hands-On project facilitation and coaching by
consultant
• Team members
• Handling resistance to change in projects
• Periodic Review by teams with management
team (weekly)
• Progress monitoring by consultant with teams
and management team
• Periodic Review by Department managers
• Training on Tools as OJT according to needs
of the projects. Key tools may be Waste
Elimination, Standardized Work, Quick
Changeover etc.
Culturalization
• Establishing
Standardized work and
metrics for
sustainability of project
results
• Training on key Lean
concepts & Tools
TWO WEEKS TWO MONTHS TWO WEEKS
Support & Training is for a maximum of 80 persons 6

7. Lean Culturalization Consultant Led Hybrid
Advantages
• Comprehensive involvement
• Concurrent improvement
• Long Term culture &
sustainability
• Involve all members
• Adopt full change
management cycle
• Higher ROI
• Quick Results
• Lower investment
• Less time spent by
management
• Quick Results
(compared to Lean
culturalization model)
• Training given in JIT
form
• Lower investment
compared Lean
Cultaralization model
• Partial change
management model
• Non pilot team
members can
participate as
observers
Setbacks
• Longer transformation period
• Higher Investment
• Limited employee
involvement
• Limited skills &
experience and culture
transferred
• Working only on one
project
• Limited employee
involvement
• Limited skills &
experience and culture
transferred
• Working only on one
project
COMPARISON OF MODELS
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8. CONSULTANTS INVOLVEMENT AT INTEL
• Consultants will be facilitating projects and skills
transfer at Intel every 3 weeks once
• Consultants will be on site at Intel for 5 days at any
planned visit
• During each visit improvement teams will be
spending time working on the improvement
projects and necessary tools, skills, coaching and
motivation will be provided by consultants
• Intel’s internal team leaders will be closing the
actions of projects between consultants’ visit.
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9. RECOMMENDED APPROACH
• It is recommended that Intel takes the Hybrid
consulting model to work on improvement
projects
• This will create results which can be seen within 3
months which can be used as buy-in to get all staff
at the lab into commitment to Lean
• Next a comprehensive culture creation phase and
knowledge transfer can be carried out based on
culturalization model
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10. LEARN-DO-MENTORING
Mentor and coach on actual implementation
Amateurs work
until they get it
right.
Professionals work
until they can't get
it wrong.
CONSULTING METHOD
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11. THE INVESTMENT
• …………..
THE INVESTMENT COST
IS A FRACTIONOF THE
VALUE GAINED
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12. FUTURE INVESTMENT
• After completion of the Hybrid consulting
model at the investment cost of ………
Intel may obtain the balance of the support
needed as per the Culturalization Model
• This support will be delivered at a cost of
………. per day to cover the remaining
necessary tools and coaching to complete
the Lean Culturalization process
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13. SELECTED CLIENTS’ ROI
Company
Description
Description of
Intervention
Savings
Amount Spent
in USD
Estimated
Returns in USD
Fortune 500
MNC in
Singapore
Lean Constraint
Management
• 30% increase in
throughput using existing
machines
• 40% reduction in Lead
Time
200,000 6,000,000
MNC in
Thailand
Lean Cultural
Transformation
through Lean
Masters
certification
• 50% reduction in
Inventory and Lead Time
• 40% increase in
throughput
• 60% reduction in
changeover time
120,000 9,00,000
Mid Size
Company in
Malaysia
Lean Value Stream
improvement.
Short training and
Projects
• 30% increase in line
productivity
20,000 3,000,000
Semicon
Giant in
Malaysia
Lean Cultural
Transformation
through Lean
Masters
certification
• 40% Reduction in
Changeover time
• 20% improvement in OEE
• 20% improvement in
Lead Time
120,000 5,000,000
Note:
• Company names have not been revealed for confidentiality purposes based on consulting practice ethics
• Returns are estimated based on a one year period during the consulting intervention which may not include recurrent savings
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14. • 20 Years experience in Manufacturing
Operations
• Engaged in Lean transformation for
Fortune 500 and small companies all
over Asia since 1999
• Former Supplier Lean Head for Asia at
Seagate Technologies
• Helped clients save Millions of Dollars
within a short period of time
• Have diagnosed, trained and
implemented Lean for clients such as:
Seagate, GE, 3M,Carsem, Snap
On, NSK, Minebea and many more
• Uses hands-on and pragmatic
approach to consulting and earned nick
name as “The Constraint Buster”
CONSULTANTS’ CREDENTIALS
• 18 Years of experience in Organization
Development and Learning
• Formed Senior Manager of OD for
PayPal and First Solar for APAC
• He is a Certified Trainer of Zenger
Miller for interpersonal and leadership
Skills
• Experienced in the area of
leadership, people
management, facilitation, team
development based on positive
psychology and practical management
experience
• His clients include TE Connectivity
China, Tan Chong Motor, Park Yard
Hotel Shanghai, Dynacraft, Green
Parket, Amanda Hotel Langkawi and
etc
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J. Ramesh Victor Laurence Yap