In temperature-controlled food logistics, operational stability and standardization are fundamental requirements to ensure safety, productivity, and reliability.
Emergent Cold LatAm has structured its own model to ensure that every facility achieves operational efficiency from day one: Emergent Way, which incorporates lean principles from planning and construction through to the operational maturity of temperature-controlled distribution centers.
Here we will explain the objective of this methodology, the criteria we use to evaluate the lean maturity of the units and the structure of our internal operational certification process.
Objective of lean methodology
At Emergent Cold LatAm, the lean methodology has three main objectives:
- Stabilize the operation, reducing the variability in critical processes such as receiving, storage, picking, loading and temperature control of food.
- Eliminate waste, such as excessive journeys of the loads, long waits, reworking and any activities that don’t add value for the client.
- Strengthen a culture of continuous improvement, guaranteeing predictability and operational sustainability in the whole network.
In operations where controlled temperature, speed and trackability need to be maintained 24/7, the lean methodology functions as the system that ensures operational discipline, reduces risks and improves performance.
The Eight Lean Fundamentals
The basis of the lean formation in a company is structured in eight fundamental essentials, applied in all units:
- Lean Culture
- Resolution of problems
- Visual management
- Analysis of flow of value
- Standardized work
- 5S
- Kaizen
- Voice of the Client
They guarantee a common understanding between operators, leaders and managers, creating operational discipline, sustaining growth.
What the lean evaluation analyzes
The lean evaluation was developed on the basis of three central pillars, which organize all the criteria and topics reviewed during the process. Each pillar brings together essential aspects to measure the degree of lean maturity of a unit and to guide its plan of evolution.
1. Leadership and Culture
This pillar verifies whether the leadership is aligned and engaged in the lean methodology and evaluates:
- Active leadership;
- Alignment on priorities and lean standards;
- Involvement of the teams in the routines and improvement practices.
The focus is to guarantee that the lean culture is incorporated into the behavior of the leaders and the operational routines.
2. Implementation of the Lean Fundamentals
Here we measure whether the lean methodology does in fact take place in the day to day operation, and evaluates:
- Training of the teams in lean fundamentals;
- Level of implementation of lean tools in the operational areas.
This pillar shows whether the practice is consolidated and is not just the theoretical knowledge.
3. Sustainability of the Lean Culture
This pillar verifies whether the operation is able to maintain the lean practice over time, with discipline and consistency, and evaluates:
- Replicability of the standards and practices between shifts and processes;
- Indicators of operational excellence that sustain continuous improvement;
- Use of Emergent Cold LatAm standards and norms which guarantee uniformity in the whole network.
This is the pillar that measures the capacity of the unit to maintain stable results and to evolve in the model of excellence.
How the evaluation process works
The lean certification process has clear stages that involve both the local leadership and regional specialists.
1. Self-evaluation of the unit
Conducted by the local team and by the Lean Champion, this stage identifies the actual state and highlights the points needing immediate intervention.
2. Official evaluation
Carried out by a regional Lean Specialist or external consultant, and which reviews the following:
- Operational evidence;
- Indicators;
- Management practices;
- Accompaniment of the action plan;
- Coherence between processes and results.
3. Report on maturity and action plan
The unit receives:
- Level of lean maturity;
- Category of corresponding certification;
- Detailed recommendations.
4. Cycle of evolution
A regional roadmap defines when each unit is to undergo further evaluations, respecting the rhythm of evolution and operational complexity.
Categories of Lean Certification
The units are classified in accordance with their level of lean maturity. The categories used are:
- Basic – initial lean structures established and stability in development;
- Bronze – lean standards and routines applied consistently;
- Silver – high predictability, consolidated indicators and continuous improvement present in day to day operations;
- Gold – robust processes, structured governance and sustainable results;
- World Class – benchmark in operational excellence, high level of standardization, innovation and superior continuous improvement.
This scale enables the evolution of the units to be accompanied over time.
Emergent Way: Lean from the ground up
Emergent Way is the proprietary model of Emergent Cold LatAm which integrates lean from the origin of the operation. This means that:
- The layout is planned with lean principles;
- The flows of movement are developed to minimize waste;
- Visual management systems are incorporated right from implantation;
- Work standards are defined before the start of activities;
- The ramp-up follows lean practices to guarantee productivity from the very first day.
The lean journey at Emergent Cold LatAm brings together methodology, governance, culture and our own model of implementation which speeds up operational maturity and establishes high standards throughout the cold chain.
With objective evaluations, internal development of talents and consistent practices of continuous improvement, each unit evolves in a solid, predictable manner aligned with the requirements for temperature-controlled logistics.
