Welcome to Lean Tours
Company Profile Summary
Welcome to Lean Tours, your gateway to discovering Japan’s world-renowned manufacturing excellence. We specialize in offering immersive, hands-on experiences that bring leaders from around the globe to Japan’s top manufacturing plants to learn about the tools and techniques behind Japan’s success in process improvement.
At Lean Tours, we focus on introducing you to powerful methodologies such as Kaizen, Lean, Kanban, and Six Sigma, which have driven the transformation of Japanese manufacturing into a global benchmark for efficiency and innovation. With over 20 years of industry expertise, our team of seasoned professionals will guide you through tailored training sessions, live factory tours, and practical demonstrations that offer invaluable insights into how Japanese companies achieve operational excellence.
Our services include:
- In-depth Training on Lean Manufacturing, Kaizen, Kanban, and Six Sigma, delivered by industry experts.
- Exclusive Factory Tours offering real-world examples of how leading Japanese companies apply these methodologies for success.
- Consultancy Services to provide tailored solutions to your specific challenges and improve your business processes.
- Lean Six Sigma Black Belt Courses to certify your team and equip them with advanced tools for driving long-term operational improvements.
- One-on-one Zoom Consultations to address your unique problems and help implement the most effective solutions.
At Lean Tours, we empower your team to adopt proven strategies for continuous improvement, productivity enhancement, and waste reduction. Join us in Japan for a transformative experience that will give you the knowledge and tools to elevate your business to new heights of efficiency and success.
About Us
At Lean Tours, we believe that understanding
and applying LEAN Manufacturing principles can revolutionize how businesses
operate, fostering a culture of continuous improvement and operational
excellence. Our mission is to provide you with comprehensive knowledge and
firsthand experiences that will empower you to implement LEAN practices
effectively in your own organization.
What You Can Expect
- In-Depth Knowledge: Dive into a wealth of resources that cover the core concepts, tools, and techniques of LEAN Manufacturing. From foundational principles to advanced strategies, we offer a complete educational experience tailored to your needs.
- Immersive Factory Tours: Experience LEAN Manufacturing in action through our guided factory tours. See real-world applications of LEAN principles and gain insights from industry experts on how these practices are applied to achieve outstanding results.
- Expert Guidance: Our team of seasoned professionals is here to share their expertise and answer your questions. Benefit from their extensive experience and learn best practices that can be applied to your specific business challenges.
- Practical Resources: Access a variety of practical tools and resources, including articles, case studies, and multimedia content, designed to help you grasp LEAN concepts and apply them effectively in your work environment.
Our Mission
At Lean Tours, our mission is to empower organizations to achieve operational excellence through the transformative principles of LEAN Manufacturing. We are dedicated to helping businesses understand, adopt, and implement LEAN methodologies that drive efficiency, reduce waste, and foster a culture of continuous improvement.
We achieve this by providing
Our Vision
Our vision is to become a leading catalyst for the global adoption of LEAN Manufacturing, setting new standards for operational efficiency and effectiveness across industries. We envision a future where every organization, regardless of size or sector, utilizes LEAN principles to maximize value, minimize waste, and drive sustainable growth.
We aspire to
Our Team
At Lean Tours, our success is driven by a dedicated team of experts with a shared passion for LEAN Manufacturing and operational excellence. Each member of our team brings a wealth of experience, specialized knowledge, and a commitment to helping organizations achieve their efficiency goals. Get to know the talented individuals behind LeanTours who are here to support your journey towards LEAN transformation.
Callum Jayakody
Founder & Director
Background
- Over 20 years in manufacturing and operations management.
- Holds a Bachelor’s and Master’s in Industrial Engineering.
- Certified LEAN Six Sigma Black Belt.
Expertise
- Strategic LEAN implementation and process optimization.
- Organizational change management.
- Dedicated to helping companies achieve measurable improvements in efficiency and productivity.
Role
- Oversees Lean Tours’ strategic direction and client engagements.
- Leads high-level consulting projects.
- Develops educational resources and training programs for LEAN Manufacturing.
Background
- Yoshi Shimomoto has over 10 years of experience in project management, facilitation, and cultural liaison.
- Holds an MBA from the Paul Merage School of Business, University of California, Irvine, and a Certificate in Digital Innovation.
- Career highlights include roles as Overseas Subsidiary Controller and Senior Controller at a leading Japanese manufacturing company and a role at EY in Turnaround and Restructuring.
- Skilled in cross-cultural communication for managing multinational projects.
Expertise
- Specializes in bridging cultural gaps and fostering effective communication across diverse regions (Americas, Europe, Middle East, Asia).
- Known for a deep understanding of cultural nuances and emotional dynamics in cross-cultural interactions.
- Experienced in facilitating Lean production tours for multinational executives.
Role
- Serves as a Cultural Liaison and Facilitator for Lean Tour participants.
- Acts as a bridge between participants and Factory Tour Managers.
- Guides global participants in experiencing and understanding Japanese Lean production while promoting collaboration and mutual understanding.
Yoshi Shimomoto
Chief Operating Officer
Dr. Sashika Sandaruwan
Director of Training and Development
Background
- Seasoned trainer and consultant with expertise in LEAN education and workshop facilitation.
- Holds MBBS degrees and is a recognized expert in adult learning and training methodologies.
- Extensive experience in the healthcare sector and LEAN implementation for Ministry of Health projects.
Expertise
- Develops and delivers engaging LEAN training programs.
- Skilled in designing customized workshops and educational materials tailored to client needs.
- Focuses on effective adult learning techniques for successful LEAN adoption.
Role
- Leads the design and execution of training programs and workshops at Lean Tours.
- Collaborates with clients to tailor educational content to specific needs.
- Ensures learning objectives are met through well-structured training initiatives.
Background
- Over 18 years of managerial and technical experience in IT sectors, including telecommunications, fintech, and digital assets.
- Held leadership roles in Sri Lanka and Japan.
- Holds an MBA and BSc.Eng (Hons) degrees.
- Certified in Six Sigma, Project Management Professional (PMP), and as a Certified Scrum Master.
Expertise
- Specializes in operational efficiency, process improvement, and project management.
- Proficient in LEAN methodologies for productivity gains and cost reduction.
Role
- Oversees daily operations at Lean Tours.
- Ensures delivery of high-quality services and maintains operational excellence across projects.
Sam Abey
Founder & Director
Callum Jayakody
Founder & Director
Background
- Over 20 years in manufacturing and operations management.
- Holds a Bachelor’s and Master’s in Industrial Engineering.
- Certified LEAN Six Sigma Black Belt.
Expertise
- Strategic LEAN implementation and process optimization.
- Organizational change management.
- Dedicated to helping companies achieve measurable improvements in efficiency and productivity.
Role
- Oversees Lean Tours’ strategic direction and client engagements.
- Leads high-level consulting projects.
- Develops educational resources and training programs for LEAN Manufacturing.
Yoshi Shimomoto
Lead Consultant
Background
- Yoshi Shimomoto has over 10 years of experience in project management, facilitation, and cultural liaison.
- Holds an MBA from the Paul Merage School of Business, University of California, Irvine, and a Certificate in Digital Innovation.
- Career highlights include roles as Overseas Subsidiary Controller and Senior Controller at a leading Japanese manufacturing company and a role at EY in Turnaround and Restructuring.
- Skilled in cross-cultural communication for managing multinational projects.
Expertise
- Specializes in bridging cultural gaps and fostering effective communication across diverse regions (Americas, Europe, Middle East, Asia).
- Known for a deep understanding of cultural nuances and emotional dynamics in cross-cultural interactions.
- Experienced in facilitating Lean production tours for multinational executives.
Role
- Serves as a Cultural Liaison and Facilitator for Lean Tour participants.
- Acts as a bridge between participants and Factory Tour Managers.
- Guides global participants in experiencing and understanding Japanese Lean production while promoting collaboration and mutual understanding.
Dr. Sashika Sandaruwan
Director of Training and Development
Background
- Seasoned trainer and consultant with expertise in LEAN education and workshop facilitation.
- Holds MBBS degrees and is a recognized expert in adult learning and training methodologies.
- Extensive experience in the healthcare sector and LEAN implementation for Ministry of Health projects.
Expertise
- Develops and delivers engaging LEAN training programs.
- Skilled in designing customized workshops and educational materials tailored to client needs.
- Focuses on effective adult learning techniques for successful LEAN adoption.
Role
- Leads the design and execution of training programs and workshops at Lean Tours.
- Collaborates with clients to tailor educational content to specific needs.
- Ensures learning objectives are met through well-structured training initiatives.
Sam Abey
Founder & Director
Background
- Over 18 years of managerial and technical experience in IT sectors, including telecommunications, fintech, and digital assets.
- Held leadership roles in Sri Lanka and Japan.
- Holds an MBA and BSc.Eng (Hons) degrees.
- Certified in Six Sigma, Project Management Professional (PMP), and as a Certified Scrum Master.
Expertise
- Specializes in operational efficiency, process improvement, and project management.
- Proficient in LEAN methodologies for productivity gains and cost reduction.
Role
- Oversees daily operations at Lean Tours.
- Ensures delivery of high-quality services and maintains operational excellence across projects.
Our Expertise in Lean Manufacturing
At Lean Tours, our expertise in LEAN Manufacturing is the cornerstone of our commitment to helping organizations achieve operational excellence. Our team of seasoned professionals brings a diverse range of qualifications, experience, and achievements to the table, ensuring that we provide the highest level of expertise and support to our clients.
Qualifications and Certifications
- LEAN Six Sigma Certifications: Our team includes LEAN Six Sigma Black Belts certified through prestigious organizations such as the SSMI – USA. These certifications reflect our deep understanding of both LEAN principles and Six Sigma methodologies, equipping us with advanced skills in process improvement and quality management.
- Industry-Recognized Training: We hold certifications from recognized institutions in LEAN Manufacturing and Continuous Improvement, including training from the Lean Enterprise Institute (LEI) and the Shingo Institute. This formal training underpins our ability to implement and teach LEAN practices effectively.
- Advanced Degrees: Our team members hold advanced degrees in fields such as Industrial Engineering, Operations Management, and Business Administration. These academic backgrounds provide a solid foundation for understanding complex operational challenges and devising strategic solutions.
Experience
- Diverse Industry Experience: Our consultants have extensive experience across a wide range of industries, including manufacturing, healthcare, automotive, aerospace, and consumer goods. This breadth of experience allows us to apply LEAN principles in various contexts and tailor solutions to the specific needs of different sectors.
- Global Reach: We have worked with organizations of all sizes, from small businesses to multinational corporations. Our global experience enables us to understand and navigate different cultural and operational environments, providing insights and solutions that are relevant and impactful.
- Hands-On Implementation: Our team has a proven track record of leading successful LEAN transformations. We have guided numerous companies through the implementation of LEAN practices, resulting in significant improvements in efficiency, quality, and customer satisfaction.
Achievements and Successful Projects
- Operational Excellence Awards: Several of our clients have received industry awards for operational excellence as a result of our consulting services. These accolades highlight the effectiveness of our LEAN implementations and our ability to drive meaningful, measurable results.
- Significant Cost Reductions: We have successfully led projects that achieved substantial cost reductions through LEAN initiatives. For example, we have helped clients reduce operational costs by up to 30% by streamlining processes, eliminating waste, and optimizing resource use.
- Productivity Improvements: Our interventions have led to significant increases in productivity for our clients. Projects have included optimizing production lines, improving inventory management, and enhancing overall workflow efficiency, resulting in productivity gains of 20% or more.
- Case Studies and Success Stories: We have developed detailed case studies showcasing the success of our LEAN implementations. These case studies illustrate our approach, methodologies, and the tangible benefits realized by our clients, including improved lead times, enhanced quality control, and increased profitability.
Commitment to Continuous Improvement
- Ongoing Professional Development: Our team is committed to staying at the forefront of LEAN Manufacturing by engaging in continuous professional development. We regularly participate in industry conferences, workshops, and training programs to keep our skills and knowledge up-to-date.
- Innovative Solutions: We continually explore and integrate new LEAN tools and techniques to enhance our service offerings. By leveraging the latest advancements and best practices, we ensure that our clients benefit from cutting-edge solutions that drive operational excellence.
At LeanTours, our deep expertise in LEAN Manufacturing is reflected in our qualifications, experience, and track record of success. We are dedicated to helping organizations achieve their efficiency and improvement goals through tailored LEAN solutions that deliver real, measurable results.
Success Stories
KC Facility Services Pty Ltd
At Lean Tours, we believe in the transformative power of LEAN Manufacturing, and our success stories illustrate how companies can achieve remarkable results by implementing LEAN principles. One such success story is that of KC Facility Services Pty Ltd, a facility maintenance company that saw significant improvements in service delivery, cost reduction, and customer satisfaction through LEAN practices.
Case Study: KC Facility Services Pty Ltd
Company Overview:
KC Facility Services Pty Ltd is a leading facility maintenance company specializing in a range of services, including janitorial, repair, and maintenance work for commercial and industrial clients. The company faced challenges in service delivery efficiency, cost management, and customer satisfaction.
Challenges Faced:
- Service Delivery Inefficiencies:
- Problem: KC Facility Services experienced delays and inefficiencies in service delivery. Maintenance requests were often delayed, and the process for handling service tickets was cumbersome and slow.
- Impact: These inefficiencies led to longer response times, decreased client satisfaction, and an overall reduction in service quality.
- High Operational Costs:
- Problem: The company struggled with high operational costs due to inefficient resource allocation and wasteful practices. The cost of materials and labor was higher than industry standards.
- Impact: Elevated costs affected profitability and competitiveness in the market.
- Customer Complaints:
- Problem: A significant number of customer complaints were received, primarily related to delayed service and unresolved issues.
- Impact: The high volume of complaints damaged the company’s reputation and strained client relationships.
LEAN Solutions Applied:
- Implementation of 5S:
- Action: The company adopted the 5S methodology to improve organization and efficiency within the facility. This included sorting tools and materials, setting in order for easy access, shining (cleaning) work areas, standardizing procedures, and sustaining these practices.
- Outcome: Enhanced organization led to a more streamlined workflow, reduced time spent searching for tools, and improved overall operational efficiency.
- Introduction of Kanban Systems:
- Action: Kanban systems were implemented to manage maintenance requests and inventory. Visual Kanban boards were used to track the status of service tickets and inventory levels.
- Outcome: This approach improved the visibility of workflow, reduced bottlenecks, and ensured that maintenance requests were addressed in a timely manner.
- Adoption of Just-In-Time (JIT) Practices:
- Action: JIT practices were introduced to manage inventory and resources more effectively. The company focused on ordering materials and scheduling labor based on actual demand rather than forecasts.
- Outcome: Reduced inventory costs and minimized waste, leading to more efficient use of resources.
- Kaizen for Continuous Improvement:
- Action: A Kaizen culture was fostered within the company, encouraging employees to identify areas for improvement and suggest incremental changes.
- Outcome: Continuous improvement initiatives led to ongoing enhancements in processes and service delivery.
- Value Stream Mapping (VSM):
- Action: Value Stream Mapping was used to analyze and optimize the service delivery process. The company mapped out the entire process from request to completion, identifying areas of waste and inefficiency.
- Outcome: Streamlined processes reduced delays and improved the overall efficiency of service delivery.
Results Achieved:
- Improved Service Delivery:
- Result: Service delivery improved by 45%. The introduction of LEAN practices streamlined the maintenance request process and reduced response times, resulting in faster and more reliable service.
- Cost Reduction:
- Result: Operational costs were reduced by 48%. Efficient resource management, reduced inventory levels, and minimized waste led to substantial cost savings and improved profitability.
- Reduced Customer Complaints:
- Result: Customer complaints were reduced by 60%. The improvements in service delivery and overall process efficiency led to higher customer satisfaction and fewer issues.
Key Takeaways:
- Effective Implementation: Successful LEAN implementation requires a comprehensive approach, addressing multiple areas of the business and involving all employees.
- Continuous Improvement: Fostering a culture of continuous improvement through Kaizen can drive ongoing enhancements and sustain gains over the long term.
- Clear Benefits: LEAN practices can yield substantial improvements in service delivery, cost management, and customer satisfaction, providing a competitive edge in the industry.
Conclusion:
The success story of KC Facility Services Pty Ltd demonstrates the powerful impact of LEAN Manufacturing principles on operational efficiency, cost management, and customer satisfaction. By adopting LEAN practices such as 5S, Kanban, JIT, Kaizen, and Value Stream Mapping, KC Facility Services achieved significant improvements, showcasing how LEAN methodologies can transform facility maintenance operations.
Baw Baw Finance
At Lean Tours, we are proud to share the impactful success stories of companies that have transformed their operations through LEAN Manufacturing principles. One remarkable example is Baw Baw Finance, a company that achieved significant improvements in its loan processing operations by implementing LEAN methodologies. Here’s a detailed look at their journey, the challenges they faced, the solutions they applied, and the impressive results they achieved.
Case Study: Baw Baw Finance
Company Overview:
Baw Baw Finance is a leading financial institution specializing in providing home loans and mortgage services to clients. The company faced several challenges related to the efficiency of its loan processing system, impacting customer satisfaction and operational performance.
Challenges Faced:
- Long Waiting Times:
- Problem: Clients experienced extended waiting periods for loan approvals. The process was slow and inefficient, leading to frustration and delays in securing loans.
- Impact: The long waiting times negatively affected customer satisfaction and the company’s ability to close deals promptly.
- Low First-Time Loan Approval Rate:
- Problem: The rate of first-time loan approvals was lower than desired, with many applications requiring multiple rounds of review and additional documentation.
- Impact: A low approval rate hindered the company’s ability to attract and retain clients and slowed down overall loan processing.
- Extended Lead Time for Application Processing:
- Problem: The lead time to lodge a loan application was 16 days, from initial contact to final submission. This lengthy process caused delays and inefficiencies in managing loan applications.
- Impact: The extended lead time contributed to delays in loan approvals and overall inefficiency in the loan application process.
LEAN Solutions Applied:
- Value Stream Mapping (VSM):
- Action: Baw Baw Finance used Value Stream Mapping to analyze the end-to-end loan processing workflow. The mapping exercise identified key areas of waste and inefficiency in the application and approval process.
- Outcome: The insights gained from VSM enabled the company to streamline workflows and eliminate unnecessary steps, significantly reducing processing time.
- Introduction of Kanban Systems:
- Action: Kanban boards were introduced to manage the status of loan applications and document flow. Visual Kanban systems were used to track application progress and prioritize tasks.
- Outcome: Improved visibility into the status of applications allowed for better management and quicker resolution of bottlenecks, enhancing overall process efficiency.
- Standardization of Procedures:
- Action: The company standardized its loan processing procedures to ensure consistency and efficiency. This included creating clear guidelines for document submission, review processes, and approval workflows.
- Outcome: Standardization reduced variability in processing times and improved the accuracy and speed of loan approvals.
- Implementation of Lean Six Sigma:
- Action: Lean Six Sigma methodologies were applied to further refine the loan processing system. This involved rigorous analysis of data and processes to identify root causes of delays and inefficiencies.
- Outcome: Data-driven improvements led to reduced processing times and enhanced accuracy in loan approvals.
- Enhanced Training and Empowerment:
- Action: Employees were trained in LEAN principles and empowered to identify and address inefficiencies in their work processes. Regular workshops and training sessions were held to promote a culture of continuous improvement.
- Outcome: Empowered employees contributed to ongoing process improvements and helped sustain LEAN initiatives.
Results Achieved:
- Reduced Waiting Time:
- Result: Waiting time for loan approvals was reduced by 45%. Streamlined processes and improved efficiency led to faster decision-making and quicker turnaround for clients.
- Improved First-Time Loan Approval Rate:
- Result: The first-time loan approval rate increased by 43%. Enhanced procedures and standardized workflows resulted in a higher rate of initial approvals, reducing the need for multiple rounds of review.
- Decreased Lead Time for Application Processing:
- Result: The lead time to lodge a loan application was reduced from 16 days to 3 days. The significant reduction in lead time streamlined the application process and improved overall efficiency.
Key Takeaways:
- Effective Process Analysis: Value Stream Mapping and Lean Six Sigma are powerful tools for identifying and addressing inefficiencies in complex processes.
- Standardization and Visibility: Standardizing procedures and using Kanban systems can greatly enhance process efficiency and reduce delays.
- Employee Empowerment: Training and empowering employees to identify and address inefficiencies contribute to a culture of continuous improvement and sustainable results.
Conclusion:
The success story of Baw Baw Finance highlights the profound impact that LEAN Manufacturing principles can have on operational efficiency and customer satisfaction. By implementing LEAN methodologies such as Value Stream Mapping, Kanban, Standardization, Lean Six Sigma, and enhanced training, Baw Baw Finance achieved remarkable improvements in loan processing times, approval rates, and overall efficiency.