Designing a World-Class Lean Academy – From Vision to Execution
Client
FCA Group, Italy
Date
March 12, 2018
Services
Agility Operations | Sustainability & Resilience
Website
Major Improvments
- Modular Space Planning
Designed a fully modular lean training space layout inspired by FCA Turin’s Academy blueprint, enabling scalable and flexible training zones. - Learning by Doing Flow
Established a U-shaped flow layout for live simulations of production, logistics, quality gates, and changeovers. - Role-Based Training Structure
Developed tiered curriculums for operators, team leaders, and engineers based on real shopfloor use cases. - Integration of KPIs & Daily Management
Embedded visual performance boards, hourly tracking routines, and digital PDCA corners for habit formation.
- Modular Space Planning
Application Scope
- New Employee Onboarding
Used as a bootcamp to immerse new hires in practical lean methods before entering real production lines. - Improvement Project Showcases
Provided a physical platform to demonstrate Kaizen projects, increasing engagement and organizational learning. - Supplier Capability Audits
Served as a verification hub to assess supplier understanding of WCM principles before nomination. - Leadership Coaching Arena
Enabled structured leadership walkthroughs and mentoring sessions based on real-time production simulation.
Customer Says
Frank Kampmann
Supplier Quality OfficerSupplier Quality Officer, BMW Stuttgart
Eddso played a critical role in optimizing our supplier value streams for key components, including touchscreens from Xiamen and starter batteries from Xiangyang. Their expertise in supplier audits and process improvements has strengthened quality control, enhanced production stability, and delivered measurable cost savings.
Sophia Chow
CEOCEO, Amazon Seller (Silk Products)
Eddso provided invaluable guidance in optimizing our silk product inventory management and internal logistics. Their tailored solutions have significantly reduced excess stock, improved fulfillment efficiency, and streamlined our operation. With their support, we’ve achieved faster turnaround times and better cost control.
Philip Clayton
Warehouse ManagerWarehouse Manager, CML Fulfilment Telford
Eddso conducted a thorough ergonomic analysis of our warehouse operations, identifying key areas for improvement in material handling and workstation setup. Their recommendations have significantly reduced worker fatigue, enhanced picking efficiency, and improved overall safety. A game-changer for our fulfillment processes!
Debbie Kübel-Sorger
Supply Chain ManagerSupply Chain Manager, Getrag Ford
Eddso supported our global team during a critical period of transition, helping us identify and resolve supply chain bottlenecks across multiple plants. Their structured diagnostics and fast-paced improvement workshops led to better coordination with Asian suppliers and improved our just-in-time delivery performance significantly.
Marco BELLINI
Global Quality Compliance OfficerGlobal Quality Compliance Officer, Brembo S.p.A.
Eddso’s VDA audit simulations and supplier validation tools gave us a fresh perspective on cross-border risk management. Their sharp insights into Chinese manufacturing standards helped us align better with our tier-2 brake system suppliers.
Aiko TANAKA
Head of Procurement & SourcingHead of Procurement & Sourcing, Panasonic Life Solutions
We engaged Eddso for a lean production diagnostics at our battery module supplier in Shenzhen. Their team quickly mapped out bottlenecks and ergonomic issues that were previously unnoticed. Their TPM-oriented solutions were both practical and sustainable.
Success Projects
Smart Supply-chain Resilience in Gear Shaft Machining
Responsive Supply-chain
Restructuring Production & Logistics in Heavy Gearbox Manufacturing
Flow Optimization
National-Level Demonstration of Visual Transparency in Special Steel
Flow Optimization
TPM & VSM Upgrade for Battery Quality Compliance
Flow Optimization