Lean Manufacturing

picture illustrating the interaction between lean and manufacturingMultinational companies like Toyota, Motorola and GE have recognized the benefits of taking a proactive approach at making their business more focused on delivering the needs of its customers. This approach focuses on two separate methodologies which have been integrated in recent years namely LEAN manufacturing to remove non-value-added activities from the business process and using the DMAIC or Six Sigma approach to solve problems or remove variability from the production/service process.


LEAN focuses on identifying only those operations which add the value which the customer specifies. All other operations are considered wasteful.


Lean Tools focus on eliminating wastes, improving efficiency and creating smooth flow in the value stream through the employment of tools such as

  • Process Mapping
  • Value Stream Mapping
  • Standardised Work
  • Mistake proofing
  • Visual Controls


Six Sigma uses DMAIC methodology approach for process improvement and variability reduction to achieve Six Sigma quality levels which effectively would all but eliminate defects delivered to the customer. Achieving Six Sigma quality would mean that the chances of a customer getting defect product are 3.4 chances in a million outcomes.


The Six Sigma approach focuses on understanding the capability of the product/service realisation process and its ability to consistently meet customer requirements using tools such as:

  • Problem Definition
  • Process Definition and Mapping (SIPOC)
  • Identification, categorisation and measurement of Variables
  • Process Capability Measurement Cp and Cpk
  • Cause and Effect Analysis
  • Failure Mode Effect Analysis (FMEA)
  • Correlation analysis
  • Brainstorming
  • Hypothesis Testing
  • Design of Experiments
  • KPI definition
  • Control Plans
  • Statistical Process Control


Our consultants are Lean Six Sigma Black Belt trained to support you in solving your process problems.


For more detailed information phone CREM Ltd at +353 (0)87 8200053 or email neil@crem.ie.


Lean Business Offer


CREM Ltd can support your company identifying your value stream and remove waste from your process. Enterprise Ireland’s Lean Business Offer is designed to encourage clients to adopt Lean business principles in their organisations to increase performance and competitiveness.


The Enterprise Ireland/IDA Lean Business Offer is made up of three levels of support:

picture of the enterprise logo1. LeanStart

2. LeanPlus

3. LeanTransform


picture of the ida ireland logoEach level of support is characterised by increasing levels of capability in implementing Lean business principles and other best practice approaches to drive company awareness, adoption and integration of Lean tools and techniques.


1. Lean Start 


LeanStart provides an introduction to Lean concepts and allows you to gain an understanding of what the tools and techniques can do for your company in a short, focused engagement. Companies can apply for grant support towards the cost of hiring a Lean consultant/trainer to undertake a short in-company assignment which will;

  • introduce Lean principles and Agile processes
  • achieve immediate cost reduction targets
  • lay a foundation for future Lean or productivity improvement projects
  • incorporate First Steps to Green Competitiveness Guidebook


Assignments will typically be carried out over eight to ten weeks. Companies will be eligible to receive support for a maximum of seven consultancy days. Maximum funding is €3,150.


2. Lean Plus 


Companies looking to undertake a Lean project over a medium-term period can apply to Enterprise Ireland for a Business Process Improvement Grant to support the costs of the LeanPlus Assignment. A LeanPlus assignment is a medium-term business process improvement project which will result in sustained use of Lean techniques and related methodologies by the company, and will achieve significant measurable gains in capabilities and competitiveness. The LeanPlus assignment should;


  • deliver significant productivity improvement and cost reductions,
  • embed a culture of business improvement and lean techniques to a cohort of trained staff, and
  • introduce a programme to pursue company-wide improvement.


Assignments may vary in size and scope but will typically be completed within six months and will not exceed a total project cost of €100,000.


3. Lean Transform 


LeanTransform is a large scale, extensive and holistic company transformation programme delivered by an external training team of international reputation. The main support mechanism is by training grant; support is available for consultancy costs for SMEs, but not large companies.


Lean Transform projects should:

  • deliver company-wide transformation in culture and productivity performance,
  • embed the competencies necessary for on-going competitiveness gains in the company, and
  • result in sustainable improvement in the business and across its supply chain.


The Lean Transform initiative is primarily designed for larger companies with significant operations who can demonstrate to Enterprise Ireland that they have existing capability and resources to implement a programme of this scale.


Assignments will typically run for at least one year. The assignment is preceded by a scoping exercise.


For more detailed information phone Neil Cremin at +353 (0)87 8200053 or email Neil@Crem.ie who is a registered Enterprise Ireland Service Provider


CREM Ltd as an approved Enterprise Ireland (EI) Service Provider can work with you to identify and measure competitiveness issues, we can introduce you to best practices in your industry, and support you by providing access to a range of competitiveness building tools, including EI Company Competitiveness Health Check, EI Lean Offer and EI Green Offe