Lean Toolbox
At Jay Hodge & Associates we have extensive experience in the application of these Lean Tools, not just in the theory and principles behind them. Each of these tools serve a specific purpose and when, used properly, will enable your organization to make measurable and sustainable improvements that become the foundation for cultural change. These tools are applicable to every process in your organization and can impact cost, productivity, quality, service, safety, and people. Our goal in any engagement is to create internal experts who are capable of continuing to utilize and train others to effectively utilize these valuable tools.


5S (Sort, Set, Shine, Standardize and Sustain)
A system to optimize process and material flow to eliminate waste and maximize value.

VALUE STREAM MAPPING
Documenting at a granular level the "Reality" of how your processes are currently designed in order to identify constraints and other opportunities for improvement.

8 WASTE REDUCTION
Identifying and addressing process interrupters that reduce the value of your output QCO (Quick Changover)/SMED developing optimal changeover processes by identifying both internal and external activities.

MATERIAL AND INFORMATION FLOW
Visual documentation of the flow of material and information in the organization to identify potential constraints and opportunities.

STANDARD WORK
Documentation of agreed upon process steps to eliminate variation and improve quality.

KANBAN SYSTEM
Material and supplies replenishment system that optimizes inventory levels based upon demand.

VISUAL MANAGEMENT SYSTEMS
Development of visual systems for the management of material, people, systems, processes, and information to improve
communication, flow, and responsiveness.

PROJECT MANAGEMENT
Establishment of documented, comprehensive, and sequential action plans to manage, monitor, and communicate the status, barriers, and required resources to support a goal or objective.

PRACTICAL PROBLEM SOLVING
Utilization of the DMAIC, PDCA, 5Why, 8D, or other problem solving systems to identify, validate, and solve the problems that interrupt our processes or consume resources without adding value.

PROCESS MAPPING
A simpler and less time consuming version of VSM to quickly identify problems and interrupters.

LEADER STANDARD WORK
Documentation of clearly defined daily, weekly, and monthly responsibilities for specific roles in order to create a recipe for success and provide consistency in management and leadership practices.

ANDON SYSYTEMS
Visual and audible systems for communicating immediate and clearly defined needs or actions.

CARDBOARD CITIES
A pre-implementation tool used to physically validate a process layout, flow, and organization.



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