A well structured Performance Assessment is typically the first step or even a pre-project activity. Depending on the size and complexity of the operations this may take 2-5 days.

Done well such a Plant Diagnostic not only documents the current performance but it reveals core issues with the existing operating and management system. It identifies and quantifies improvement potential and describes necessary improvement steps.

Typically tools such as: Value Stream Mapping (VSM / MIFA), Parts Quantity Process Routing (PQPR), Work Balance, Core Cost Driver Analysis, Multi Moment Studies, Variability Studies are used to reveal and visualize existing weak points.

The decision which diagnostic tools and procedure to be taken and if tools needs to be modified match the specific client needs is an important step at the beginning of any assessment 

Often a special Lean Production System Assessment is used. This qualitative assessment rates the current level of lean implementation based on a 5-point scale.

It judges 20 key elements of lean using clear descriptions at each level to avoid rating discussions. This aligned picture of the current level of a lean transformation together with the identified weak points can now serve as a starting point for further focused improvements of the system or procedures.