Unleash the Power of Lean

Transform Your Manufacturing Operations

Welcome to a world where operational challenges meet their match. As a Manufacturing Leader, you’re on the frontline navigating through a maze of increasing costs, inefficiencies, and quality concerns that threaten to undermine your hard-earned success. At Engineering Possibilities, we understand the gravity of these issues and the impact they have on your bottom line and reputation.

You’re battling on multiple fronts – soaring operating expenses, productivity bottlenecks, and quality issues that erode customer trust. Overproduction, excessive waste, and extended lead times are not just operational nuisances; they’re barriers to your growth and competitiveness in a fast-paced market.

Enter Lean – not just a methodology, but a transformative philosophy designed to streamline your operations, enhance quality, and significantly reduce costs. Lean is about doing more with less, focusing on value from your customer’s perspective, eliminating waste, and empowering your team to think, act, and innovate towards continuous improvement.

At Engineering Possibilities, we specialize in making Lean not only accessible but highly effective for small to mid-size manufacturing companies. Through personalized consulting and dynamic training sessions, including our unique Chaos Racing simulation, we bring the principles of Lean to life. Our approach is hands-on, engaging, and tailored to address the specific challenges and opportunities within your operations.

Imagine a future where every process is optimized, waste is minimized, and your team is energized by the improvements they contribute to daily. This is not just a vision; it’s a tangible outcome of embracing Lean with Engineering Possibilities. Let’s work together to transform your operational challenges into your competitive advantage.

Creating Lean Possibilities

Lean Consulting

Elevate the performance of your operations with our Lean Consulting Services including Lean Assessments, Process Mapping, Kaizen Events, and 5S Transformations

Small Businesses

Unlock the potential of your business and enjoy lower costs, efficient processes, and larger profits with our Lean Entrepreneur Program,  Grow your Business Beyond You

Lean Training

Unleash the power of Lean in your organization with our virtual and in-person Lean Training Programs for White Belt through Black Belt Certifications

Chaos Racing

Chaos Racing is a fun and memorable workshop designed to introduce your teams to Lean

Build 30 race cars in 20 minutes, how hard can it be?

Transform your Operations Current State

Create an Efficient and Lean Future State

High Production Costs

Inefficient processes that consume time and resources, and drive operating costs up and over budget

Long Lead Times

Excessive order processing time and delays that impact customer satisfaction and on-time deliveries

Cashflow Challenges

Inefficient workflows and unproductive processes that tie up cash and delay revenue generation

High Inventory Levels

Excessive inventory of raw materials, WIP, or finished goods that inflate operating costs and create storage problems

Frequent Quality Issues

High scrap and rework rates that increase operating costs, require reprocessing and create production delays

Process Downtime & Delays

Equipment breakdowns, slowdowns, and delays that impact the manufacturing process and increase operating costs

No Visibility of Process Performance

Difficulties with data collection and tracking of process performance metrics that impacts decision making

Inefficient Process Layout

Poorly organized workspaces that lead to excessive and unnecessary movement and transportation waste

Lower Production Costs

Lower costs and improved process efficiency  achieved by eliminating and reducing process waste

Faster Processing Speed

Faster order processing time, increased production capacity, higher and more reliable production rates

Shorter Changeover Times

Faster transitions and minimal downtime between product runs, increased process flexibility 

Optimized Inventory Levels

Reduced inventory carrying costs, lower risk of inventory shortages, increased ability to meet customer demand

Improved Quality Performance

Fewer defects, lower scrap rates, higher product quality, elimination of common sources of defects and errors

Improved Capacity Utilization

Decreased process downtime, improved operating efficiency and reliability, higher production rates

Standardized Processes

Standard Work procedures and practices that effectively manage production processes and ensure high quality outputs

Continuous Improvement Culture

Data-driven decision making that elevates process performance, Lean Training that empowers employees

36%

Average Process
Efficiency Improvement

42%

Average Process
Waste Reduction

80% – 100%

Elimination
of Re-Work

Takt Time: Lean Manufacturing’s Mysterious Metric
Takt Time: Lean Manufacturing’s Mysterious Metric In the lean manufacturing world, Takt Time is frequently misunderstood, and often mistaken for its dance partner, Cycle Time. So what exactly is Takt Time, how do you use it, and how it is distinct from Process Cycle...
Brewing Efficiency: Embracing Lean Manufacturing in the Craft Beer Industry
In the world of craft beer, lean manufacturing might seem like an unexpected guest in the taproom. However, the opportunity for breweries to embrace lean principles is a game-changer that can revolutionize operations, enhance quality, and pour a glass of efficiency....
Goldilocks, the Three Bears and Just Right Inventory Levels
In the story of Goldilocks and the Three Bears, Goldilocks sought perfection—a bed, a chair, and porridge that were "just right." This analogy mirrors the quest for the "just right" inventory balance in the context of Lean transformation in a manufacturing plant....
Unlocking Potential: Distinguishing the 6 Big Losses in Manufacturing Operations
For manufacturing operations, recognizing and addressing inefficiencies is the key to unlocking the full potential of a business. The concept of the 6 Big Losses offers a strategic framework for identifying and mitigating common challenges that impede operational...
10 Common Problems Faced by Manufacturing Operations
For manufacturing operations the journey towards operational excellence is often marked by a series of challenges. Understanding and addressing these challenges is pivotal for organizations aiming to thrive in the dynamic world of manufacturing. In this blog post,...
Everything You Need to Know about Yield Optimization
In Lean Manufacturing, optimizing efficiency and minimizing waste are the focus. One powerful tool that plays a pivotal role in achieving these goals is Yield Analysis. In this blog post, we’ll look at how to perform Yield Analysis, exploring its significance,...
Quality Metrics to Empower Your Success
In Lean Manufacturing, the pursuit of operational excellence extends beyond efficiency and waste reduction to include quality. To measure and improve quality performance, Lean Practitioners rely on key metrics such as First Time Right (FTR), Throughput Yield (TPY),...
The 8 Deadly Wastes
Process Waste is defined as any process step or action that does not add value to the customer of the process. By eliminating process waste, only process steps that add value to the Customer remain. Lean Process Improvement is about streamlining processes, reducing...
The Art of Sustaining Lean Transformations
Embarking on a Lean Transformation journey is a commendable feat, but the true measure of success lies in sustaining those improvements over the long term. In this blog post, we'll explore 15 key strategies to ensure the longevity and continuous success of Lean...
Small Businesses, Big Problems
For small businesses, the path to success is often marked by a series of challenges that demand innovative solutions. From the confusion of undefined processes to the complexities of rapid growth, each hurdle provides an opportunity for growth and improvement. This...

"The most dangerous kind of waste is the waste we do not recognize."

– Shigeo Shingo, Japanese Industrial Engineer

"We are doomed to failure without a daily destruction of our various preconceptions."

– Taiichi Ohno, Japanese Industrial Engineer, Father of the Toyota Production System

"What gets measured gets improved."

– Peter Drucker, American Management Consultant

"We cannot solve our problems with the same thinking we used when we created them."

– Albert Einstein, Physicist

"If you can't describe what you're doing as a process, you don't know what you're doing."

– Dr. W. Edwards Deming, American Statistician

"There is nothing so useless as doing efficiently that which should not be done at all."

– Peter Drucker, American Management Consultant