Are your operations broken—or were they just designed that way?

In most organizations, performance issues are tackled only after they surface—when delays, cost overruns, and customer complaints are already hurting the business. But what if you could eliminate these issues before they even start?

Design for Lean (DFL) is a smarter way to build efficiency, quality, and speed into your operations—right from the design stage. At BMGI India, we help companies shift from reactive fixes to proactive planning using DFL, ensuring that every process, product, or system is built to deliver from day one.

What Is Design for Lean?

Design for Lean is a structured approach to embedding Lean principles into the early design phase of any business system. Instead of correcting inefficiencies later, DFL prevents them by:

• Mapping the full value stream before execution
• Eliminating non-value-adding steps from the outset
• Aligning design decisions with strategic goals
• Using data-backed simulations to validate assumptions

The result? Streamlined operations that are faster, cheaper, and more reliable—without the need for costly rework later.

What’s in It for Your Business?

Companies that apply DFL consistently report:

• 30–40% reduction in cycle times
• Improved cost control through waste elimination
• Higher customer satisfaction due to consistent delivery
• Stronger alignment across teams from day one

It’s especially valuable for businesses:

• Launching new product lines
• Scaling up operations
• Redesigning processes during transformation initiatives

Why Operational Problems Begin at the Design Stage

Most bottlenecks, delays, and inefficiencies don’t start on the shop floor—they start in the planning room. Poor assumptions, lack of cross-functional input, and unclear requirements often lead to:

• Broken workflows
• Frequent rework
• Underperforming systems

DFL addresses this by ensuring design teams:

• Understand the full process flow
• Eliminate design-phase waste
• Build cross-team clarity early on

BMGI India's Approach to DFL

Our consultants use a structured yet practical methodology:

• Requirement analysis aligned with business strategy
• Risk identification before execution begins
• Cross-functional collaboration to avoid silos
• Design validation through simulations and metrics

Results That Speak for Themselves

Here’s how DFL has delivered real impact:

• A consumer products company cut new product development time by 30%
• A chemicals manufacturer improved plant throughput by 20% with zero capital spend
• A logistics firm reduced last-mile delivery costs by 25% through smarter route planning during the design stage

Rethink the Way You Build