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Case Studies from recent activities:

* Principal consultants throughout Asia Pacific with a major Automotive Company

• Inventory reduction exceeding $8M AUD

• Productivity Improvements exceeding $5M AUD

* Lead consultant with a major Footwear Company 

• Totally re invented shoe manufacturing methodologies

• In Plant Lead time reduction of 80%

• In Process Quality Improvements of 70%

• Significant re-design of value streams – Both physical and cultural

• Significant cost savings – remains confidential with client

• Development of internal self sufficient lean experts

* Lead consultant throughout Asia Pacific with a major Pharmaceutical Company

• Productivity / Quality improvements leading to 40% capacity gains

• Introduction of “flow” concepts in a traditionally batch based industry

• Development of regional internal self sufficient lean experts

* Lead consultant with a Major Japanese Construction Equipment Manufacturer

• Mitigation of Capital Expenditure while absorbing 35% volume increases

• Operation now used as a benchmark / training ground for global operations

• Developed internal lean capability to expand improvement activity throughout company 

* Advisors to a Lean Pioneer Australian Hospital with project improvements throughout the organization

• Re streamed Emergency Triage to eliminate constraints and increase Emergency throughput by 25%

• Application of Standardized Work in wards resulting in 30% improvement in bed turnover

• Visual Management techniques applied throughout. Result: Improved Productivity, Reduced Errors and Improved Morale
  
  

University of Michigan

I have had the privilege to work with Tony for 5 years as part of a project to transform Caterpillar plants in Japan and China to TPS principles.  It was immediately apparent to the client that what Tony was doing was different from other consultants they had worked with.  He was not "deploying lean tools," but instead developing their management and workers to see and eliminate waste.  There are many consultants who used to work for Toyota but a very small number who got the traditional, rigorous TPS training that Tony received in Australia.  He learned TPS in the Toyota plant but was also trained by a TPS group originally formed by Taiichi Ohno and had to transform supplier plants to achieve very challenging goals.  Tony learned from the best and it shows in his ability to lead a transformation and develop other people.

Jeffrey K Liker
Professor, Industrial and Operations Engineering
University of Michigan
Ann Arbor, Michigan 48109-2117

Nike

The Nike Lean journey began like many others. It was 1998 and we had issues with our manufacturing supply where our strategic objectives were outpacing our ability to deliver capabilities. So we called in the Lean experts who quickly informed us that our situation was much too complicated, we didn't own our manufacturing, our contract suppliers were spread throughout SE Asia and the workforce was for the most part made up people migrating in to the factories from the rural farming communities with little to no manufacturing experience. Not a great beginning, that was until we had the pleasure of meeting Tony McNaughton. Tony saw our situation as a great challenge. His years of experience in the Toyota Support Center gave him the confidence and expertise to know that given the right level of commitment by Nike and the Factory leadership, that Lean would revolutionize our industry. Tony was right, his unwavering commitment to our journey over the past 10years has in fact revolutionized not only our manufacturing operations but also our business enterprise. Tony has proven himself a very competent strategist as well as thorough and persistent practitioner of the purest form of Lean, the type that only someone with his years of service and training at Toyota could have. When partnering with Tony, you can be assured that his advice comes from experience and knowledge. A critical and very difficult skill to find in contracted support. I think that it is fair to say that we wouldn't be anywhere near where we are today without Tony's on-going support and never ending encouragement.

Steven Castellanos
Lean Enterprise Director, Nike Inc.

TWI Network

Tony McNaughton is a rare lean talent.  As part of his experience working with Toyota, Tony was personally provided advanced training in the art and science of production system transformation by one of Toyota’s top TPS experts, Mr. Nakayama, former head of Toyota’s famous Operations Management Consulting Division and direct disciple of Taiichi Ohno. 

Tony possesses a rare combination of lean skills, with the ability to do everything from standardized work for production operators to entire operating system design. Tony is comfortable and effective working with plant floor workers, communicating with engineers, and coaching senior managers.  

I have had the opportunity to work with Tony and see up close the results of his lean consulting handiwork.  I can recommend Tony in the highest terms as a senior lean sensei to any manufacturer, anywhere. 

John Shook
President, TWI Network, Inc.
Senior Advisor, Lean Enterprise Institute

Glossary of terms used in the Toyota Production System

www.toyotawayacademy.com

www.landp.com.au

www.lean.org.au

www.txm.com.au