Breakaway Lean - 50/50/20 in Six Months

by Chad Kymal published on June 08, 2021

Omnex Lean approach is a highly structured results-oriented process that guarantees results in a relatively short time frame of six months. What does 50/50/20 mean? It means that an organization practicing Breakaway LeanTM can achieve a 50% reduction in inventory, a 50% increase in throughput, and a 20% reduction in operational cost in six months.

Omnex Lean process starts with an assessment that is made up of three parts - Culture, Tools, and Lean Scorecard. A Lean process has to work on all three of these dimensions: the lean culture has to be in place, the organization has to learn the lean tools, and an initial scorecard has to be taken to understand the opportunities for improvement. The most important of these three dimensions is the need for the correct culture: the lean vision, the roadmap, top managements' commitment, tie into the organizational goals and budgets, appraisal process, and the communication to the workforce.

Based on the assessment, the organization working with Omnex will create a Lean Roadmap. In conjunction with other improvements and opportunities, the Roadmap usually takes the form of a Business Excellence Roadmap. e Lean Facilitators are corporate champions, members of top management that own the value stream, and Omnex lean experts. Lean team leaders direct the project, while the project team is a cross-functional group working in the value stream and support streams.

About the Author

Chad Kymal is the CTO and founder of Omnex Inc., an international consulting and training organization headquartered in the United States. Chad is also the CEO of Omnex Systems, an enterprise quality, and IMS software provider. He is on the ISO/TC 176, ISO/TC 207, and PC 283 committees for ISO 9001:2015 (Quality Management), ISO 14001:2015 (Environmental Management), and ISO 45001 (Health and Safety Management Systems). Chad is also the U.S. expert for the ISO 10013 documented information update. He is a certified lead auditor for IATF 16949, ISO 14001, ISO 9001, FSSC 22000, HAACP, ISO 45001, and AS9100. Chad teaches these and many other courses for Omnex, such as integrated management systems. Chad and Omnex teach, implement, and audit AIAG 4th Edition FMEAs, AIAG-VDA FMEAs, and SAE J 1739 FMEAs. Chad, along with Greg Gruska of Omnex, originally discovered the linkages between the PFMEA and DFMEAs in the 1980s and 1990s.


Chad Kymal

Chad Kymal is the CTO and Founder of Omnex Inc. He is the author of seven books and more than 100 papers including several on integrated management systems. Chad is currently on the writing committees for several standards including TC 22/ SC 32/WG 8 for ISO 26262 (Functional Safety), ISO/TC 176 for ISO 9001:2015 (Quality Management), ISO/TC 207 for ISO 14001:2015 (Environmental Management), and PC283 for ISO 45001 (Health and Safety Management Systems). He founded and was the CEO of an Automotive registrar for over 10 years and is familiar with conducting audits, being witnessed for audits, and also evaluating auditors and assessors. He authored and teaches a course for 3rd Party Auditors for Automotive Registrars on behalf of International Automotive Certification Bodies Association (IACBA). This course explains how 3rd Party Auditors audit IATF 16949 in an environment that includes ASPICE, Functional Safety and Product Cybersecurity. He is currently rolling out the course to global 3rd Party Auditors for IATF 16949. Chad has spent over 20 years in system, hardware and software development in various capacities. He assesses and works in automotive system, hardware and software for Agile, ASPICE, and Functional Safety ISO 26262. Chad is also currently an intacsTM certified Principal Assessor for Automotive SPICE.