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Strategos Lean Manufacturing


Lean Mfg. & Operations

Here you will find many articles explaining Lean Manufacturing and Operations as well as the various elements. There are tools for analysis, downloads of Excel templates and forms. There are simulations and many real-life examples.

Facility Planning & Plant Layout

Facilities (land, buildings, equipment) provide the physical capability to add value and create products. The most common manifestation of facility planning (or lack thereof) is the Plant Layout. An effective layout incorporates and enables the manufacturing strategy on which it is based. Mr. Lee has authored two books and many articles on Plant Layout and Facility Planning. 

Kanban for The Job Shop

Kanban is normally thought of as a lean technique for repetitive, high-volume environments. But many job shops can use kanban for all or part of their scheduling. We just have to approach it from a different perspective. If your shop has high variety and low volume, this unique approach to kanban may be able to simplify scheduling and speed deliveries. Our new web page, Kanban For The Job Shop, discusses the what, when and how. This page is based on my upcoming presentation at the  Institute of Industrial and Systems Engineers annual conference

Mfg. & Operations Strategy

Manufacturing Strategy flows from the premise that a factory design, as any engineering design, is a compromise between competing objectives and various constraints. We can optimize the design for one or two objectives (such as cost, quality, delivery, new products) but not all. Manufacturing Strategy starts in marketing. It asks questions such as:

  • How do we intend to compete? or...
  • Why do customers buy from us instead of the competitors?

The answers lead to "Key Manufacturing Task(s)." Manufacturing must excel at this task to win orders in the marketplace. The task may be cost, flexibility or another of several dimensions. From this Key Manufacturing Task, a set of policies flow that guide daily operations and decisions for purchasing equipment, setting priorities or designing a layout (for example).

Lean Manufacturing Consulting

Use the Past–Manage the Present–Prepare the Future

Our mature and experienced consultants offer more than just technical expertise. Through hundreds of projects we have learned to build consensus and merge our knowledge with the knowledge of the client. Use Consulting for:

  • Intractable-Recurring Problems

  • Disagreement/Strong Opinions

  • Too Much Agreement

  • Once-In-A-Decade Designs

Strategos consulting projects range from quick assessments to the planning of major factories, offices  and warehouses. We can guide the development of your Manufacturing Strategy at the highest level or assist 5S on the factory floor. We can execute all of the work or guide a mixed project team. Strategos Consulting>>

Strategos Lean Training


Give your people the skills to solve their own problems. We provide lean training that addresses the specific situations they face every day. Often with a case study from your own facility. The result is a trained cadre of employees and:

  • A Problem Solved

  • A Workcell Designed

  • A Value Stream Mapped

  • A Process Simplified

Strategos training employs proven principles of Adult Learning. It is full of videos, dialogue, exercises and experiential learning. Instructional methods alternate frequently to maintain interest and address the learning modes of individual participants. Our "Learning Team" approach engages participants, increases discussion and allows for large overall sessions (50 or more).  Standard  Lean Training Programs >>

Our Expertise

Manufacturing StrategyManufacturing Strategy

Forge Your Most Potent Competitive Weapon

 A well-thought-out Manufacturing Strategy flows from and supports marketing by optimizing those factors that bring success in the marketplace (e.g. quality, customization, price, delivery). We have been employing the work of Wickham Skinner, Wheelwright, Hill and others in practical situations for several decades. 

Lean Manufacturing

Lean Manufacturing

Streamline Operations: Quality—Productivity—Speed

Strategos consultants have been designing and implementing Lean Manufacturing for many years.  We have contributed to the literature of Lean through hundreds of seminars, articles and papers as well as with this website. Through this experience we have developed procedures, rules of thumb and techniques to bring Lean to industries where the concepts seemed inapplicable.

Facility Planning & Plant LayoutFacility Planning & Layout

Make the Most of Space & Workflow

Strategos consultants have written three of the most popular books on facilities planning. We have done hundreds of facility plans from site-level to workstation level using our systematic and structured approaches.

Cellular ManufacturingCellular Manufacturing

Integrate People, Process, Product & Technology

Mr. Lee has been designing and implementing workcells for more than 30 years. While Toyota cells are ideally suited for Toyota, they do not work well in many non-Toyota environments. Our structured design approach helps design optimum workcells in a wide variety of environments, including many job shops.

Value Stream & Process MappingValue Stream & Process Mapping

Make Any Process Smoother, Better & Faster

Let us assist you with improving any of your processes using VSM, Process Mapping and other improvement techniques. Mr. Lee's popular book on the subject can be a starting point for your workshop or guided Kaizen Event. This is a "must" for any Lean Implementation or Workcell Design.

Warehousing & Supply ChainWarehousing & Supply Chain

Reduce Inventory, Stockouts & Space

Sims Consulting Group, a Strategos Affiliate, literally "wrote the book" on warehousing with the U.S. Navy's 800-page publication NS529. Ed Phillips is one of the foremost authorities on Warehousing, Supply Chain and Materials Handling.

Human Side of LeanThe Human Side

Leverage Your People

People are an integral part of every manufacturing system. As such, their needs and limitations must be accommodated and integrated with equipment, layouts and systems for best results. We start with the Socio Technical Systems (STS) approach originated by Eric Trist to ensure that people and culture are woven into every design

Lean OfficeLean Office/Administration

Streamline Your Most Wasteful Activities

There is nothing fundamentally different about an office; work is work. The same principles apply to factories, offices, hospitals and every other purposeful activity. Strategos has been applying Lean methods to administrative activities and knowledge work for many years.

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The Strategos Guide To Value Stream and Process Mapping goes  beyond symbols and arrows. In over 163 pages it tells the reader not only how to do it but what to do with it.

Strategos Guide to Value Stream & Process Mapping

Lean Briefing is only sent to those who subscribe or those who download from the Strategos website.

Books & Videos

Guide to Cycle Counting

Warehouse Planning Guide

Human Side of Lean Video

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PUB FEB 2016