Lean Engineering Black Belt™ Certification
The Lean Engineering Black Belt™ equips leaders to deliver measurable, lasting transformation inside their organizations. This immersive program goes beyond theory—participants will demonstrate their skills through a real-world implementation project, producing documented, third-party–reviewed results that drive both operational and financial improvement. Upon completion, graduates will receive a Lean Engineering Black Belt™ certificate, validating their mastery of advanced Lean tools and their proven ability to lead organizational change. With this certification, professionals gain not only the knowledge but also the credibility to optimize performance and guide their teams toward scalable, world-class operations.
Onsite Operational Assessment
An average Operational Assessment yields 7 figures of additional profit opportunity. With the onsite Operational Assessment, our team will dive deep into your operation to understand all inefficiencies that are inhibiting maximum profitability to your organization. Your team will be a part of this collaborative process, and we will spend time with each of the key stakeholders to truly understand the complexities of your business, prior to presenting the findings. Our team will uncover massive opportunities for quick transformation to an optimized operational state.
Improved Product Flow
Based on the principles of Industrial Engineering, we first will value stream map your product’s flow from start through finish, uncovering all bottlenecks and delays that occur. Next, we will first propose, and then implement a lean value stream, reducing or eliminating bottlenecks and delays to your product’s flow. Your plant layout may be impacted by improving the flow.
Plant Layout Optimization
For the plant layout optimization, we will understand both your current state layout, as well as your desired future state needs. Factors such as product flow, company growth, equipment utilization, and product value streams will all be considered to produce an optimal future state.
Supply Chain Profit Roadmap
This service will provide you with a tailored, executable Supply Chain strategy to increase your company’s profits. Targeted increase in profits is between 6 and 7 figures, annually. A Supply Chain survey relative to your business' pain points and current state will be provided to kick-start the engagement.
Throughput Optimization
We will optimize your line throughput to achieve – on average 27% more throughput. By first conducting Industrial Engineering time studies across your product lines, activities such as bottleneck reduction, line delay mitigation, set-up and changeover reduction, as well as optimized material flow will all follow. Labor and line standards will be developed in supporting the throughput optimization.
Labor and Line Standards
By evaluation your processes, The VIRATA Group can create labor and line standards that allow for increased throughput, while optimizing your labor cost. General results yield 20% (+) in labor productivity improvement.
Capacity Improvement
We strive for massive capacity improvement, often yielding 20% (+) additional capacity for your company. Industrial Engineering techniques will be deployed to accommodate this capacity increase.
Maintenance Programs
We implement P.M. programs and Work Order systems to streamline and improve uptime for your plant. We can either vet and help you select a P.M. system or implement your existing software. The VIRATA Group does not sell or represent any software or hardware companies.
Changeover Reduction
A 50% reduction in changeover time is what we strive for hitting. We will perform excessive time studies, and therefore identify all internal, external, and parallel activities associated with your changeovers. Next, we will implement an optimized changeover, training all parties involved with the changeover.
Setup Reduction
Similar to changeovers, we strive for a 50% improvement in time that it takes to setup a line, or product. The techniques used for the changeover reduction are just as vital to setup reductions. We will implement the improved setup program, along with training your team.
Scheduling Optimization
Scheduling Optimization takes several factors into account such as: plant performance, demand, planning, inventory readiness, availability, and other factors. The ultimate deliverable is an optimized schedule, thereby increasing run-time availability and plant performance.
Cycle Counting Program
Inventory accuracy is critical to a healthy supply chain. By implementing a cycle counting program, your company can strive to achieve 99% (+) in inventory accuracy. Our team will work with your key inventory personnel to develop, implement, and train your team on preserving integrity in your inventory counts.
Warehouse Optimization
We will evaluate your warehouse activities and develop solutions to optimize your Warehouse activities such as: Receiving, Put away, Picking, Shipping, Storage, Labor Productivity. Other items evaluated for optimization include warehouse layout and storage optimization. The VIRATA Group can even source additional racking for your warehouse to maximize the number of pallets stored on-hand (if needed).
Fractional Engineer Resource
Our team of Engineers can be an interim solution for your operation, in a fractional capacity. Each client’s needs are unique, and we tailor our solution to your needs.
Equipment Sourcing
Often clients that need equipment sourcing are looking to spend more than they need for the solution that will suit them. The VIRATA Group and our team of engineers does not represent any automation, hardware, or software companies. We simply vet and find the options that are suitable for your company’s needs.
KPI / Metrics Program
By defining what is important to your organization, we will help you measure what you treasure. We will develop metrics that move the needle for your organization. By performing a baseline of where you are – and then defining where you need to be – The VIRATA Group will create a unique dashboard of KPI’s / Metrics for you.
5S
The VIRATA Group will take on an area or line and 5S it so that everything has a well-defined place to reside. Once everything has been standardized, upkeeping that line or area will no longer be a chore, but rather the standard.
Audit Preparation
The VIRATA Group can help your team prepare for an audit, and break down the steps to achieve preparation, along with the timeline and key stakeholder’s actions. Passing an audit can be a monumental preparation, and The VIRATA Group participates in helping clients get there.
Lean Black Belt Certification
The VIRATA Group can provide Lean Black Belt training and issue you and your team a Lean Black Belt Certification, upon successfully completing the course.