Implementation OF "LEAN MANUFACTURING"

On this page we talk in detail about this service and you can request a personalized Commercial Offer

GET OFFER
OPTIMUM will perform an expert assessment of the current situation in your company and propose measures to improve it.

Our tasks are:
  • Evaluate the areas where you are losing funds;
  • To assess the level of achievement of your Production System (if you have one) / Analysis of the possibility of using elements of "Lean manufacturing";
  • To develop an optimal Production System taking into account the "bottlenecks" of your company;
  • Plan actions for the implementation of the Production System;
  • Provide training to your employees on Lean manufacturing tools and methodologies;
  • To conduct workshops-training in Working Groups (Kaizen-Gemba) on the introduction of elements of "Lean manufacturing";
  • Conduct a regular assessment of the degree of implementation of the Production System;
  • During theoretical and practical (in Working Groups) training, involve your staff as much as possible in the process of Continuous improvement.

LOSS ASSESSMENT/ ANALYSIS

OPTIMUM experts perform assessment/analysis:

  • existing flows using the Value Stream Map:
  • the level of defects (production of low-quality products /re-processing of substandard products or their disposal);
  • inventory levels (surpluses of raw materials, semi-finished products and finished products);
  • the level of overproduction of products (above the needs of subsequent processes);
  • the level of waiting losses (late delivery of components or semi-finished products, equipment downtime, organizational losses, flow inconsistency);
  • the level of losses due to excessive movements during operation;
  • the level of excessive processing (work that does not bring value to either the client or the enterprise;
  • opportunities missed due to inefficient use of the creative potential of the workforce.

ASSESSMENT OF THE ACHIEVEMENT OF THE CURRENT PRODUCTION SYSTEM / ANALYSIS OF THE POSSIBILITY OF USING ELEMENTS OF "LEAN MANUFACTURING"

If you apply your Production System, we will assess the status of its achievement and adjust plans and actions according to the areas that require improvement.

Otherwise, OPTIMUM experts will offer you the development of a Production System for your company.

DEVELOPMENT OF AN OPTIMAL PRODUCTION SYSTEM

After analyzing each process for adding value to the product, we will develop YOUR optimal Production System, prioritizing those areas where the greatest losses were found.

ACTION PLAN FOR THE IMPLEMENTATION OF THE PRODUCTION SYSTEM

After developing an optimal Production System, taking into account the most important and urgent elements to reduce costs, OPTIMUM experts, together with representatives of your company, will plan a phased implementation of the Production System.

TRAINING IN LEAN MANUFACTURING TOOLS AND METHODOLOGIES
We will provide training to your employees on the elements of Lean manufacturing. We will teach you how to use certain tools and techniques correctly.
We will explain:
  • what are the elements of the Production System aimed at?;
  • what advantages does a company get when implementing Lean manufacturing elements?;
  • and we will share the practical results of the implementation of the Production System at other enterprises.

WORKSHOPS-TRAINING IN WORKING GROUPS ON THE IMPLEMENTATION OF LEAN MANUFACTURING

OPTIMUM experts, right at the epicenter of the occurrence of losses, will conduct workshops-training in Working Groups (Optimum-Kaizen), for practical testing of the use of the tool / methodology of the implemented element of Lean production.

To determine the effectiveness, you will get an excellent opportunity to compare the "Pilot Zone" where Optimum Kaizen was carried out with other areas that were not affected by changes.

REGULAR VERIFICATION OF THE DEGREE OF IMPLEMENTATION OF THE PRODUCTION SYSTEM

We regularly check the achievement of the set goals for the implementation of the Production System.

Practically, this happens as follows:


  1. An optimal Production System Is Being Developed;
  2. A "Roadmap" of the stages of implementation of the Production System is being drawn up (according to the company's priorities), responsible persons, dates;
  3. The "Pilot zone" is selected;
  4. The improvement coordinator responsible for the implementation of the Production System/its elements is determined;
  5. According to the planned dates, OPTIMUM experts conduct theoretical and practical training in the "Pilot Zone";
  6. The trained coordinator implements the learned methodology (applies the tool) in the remaining zones according to the planned dates;
  7. After a jointly defined period (2-3 months), the OPTIMUM expert checks the distribution status of the element in the enterprise;
  8. Further, paragraphs 5, 6, 7 are repeated for the next elements of the Production System to be studied, according to the terms of the Roadmap;
  9. + EVERY YEAR, a total verification of compliance with the Production System is carried out, within the framework that the company has chosen for itself. After verification, a quantified status is assigned.
  10. Next, adjustments are made to the implementation plan to eliminate the detected inconsistencies.

INVOLVEMENT OF THE COMPANY'S EMPLOYEES

"Learning at work" is our motto! We treat our clients as colleagues (members of a single team). Working in working groups, hand in hand with the company's staff, the employees of the client's company are trained in tools and techniques and can successfully use them in the future for independent application.

EXPERIENCE

OPTIMUM's experts have extensive experience in the practical implementation of Production Systems / elements of Lean Manufacturing in such areas as:

  • Implementation of corporate Production Systems at the new plant of the company with "0";
  • Implementation of changes/improvements to an established Production System;
  • Organization and leadership of multifunctional Working Groups aimed at reducing losses / introducing elements of Lean Production;
  • Improving the corporate Production System / working out / presentation / defending the need for implementation / implementation;
  • Development of an Optimal Production System based on world best practices (Toyota Production System, Lean Manufacturing, etc.);
  • Development of documentation that simplifies processes: organization, collection of statistics for problem analysis, visualization, etc.;
  • Successful application of Lean Manufacturing tools and techniques; Development of training materials;
    • 5S: An Increase in the % of the implementation of the Workplace Organization System. Real experience of increasing from 35% to 98% in a specific production;
    • Standardization of processes: development of standard technological maps / visualization / simplification of training / reduction of defects / increase in productivity;
    • Kaizen: implementation of a continuous improvement System / involvement of staff in generating ideas aimed at improvement / more than 700 submitted proposals/year (more than 40% self-implementation) à exchange of best practices;
    • TRM: Reduction of downtime due to equipment breakdowns by increasing the % implementation of the Universal Equipment Maintenance System;
    • SMED – Reduction of conversion time by more than 50%;
    • Yamazumy-Work Balance Board:Red Angle – reducing the level of defects due to the Quality Incident Management System;
      • Reducing the number of personnel required for the process by rebalancing the lines;
      • Reducing process time by identifying non-value-adding operations, followed by elimination/reduction;
    • Working Groups – A system for organizing a Work Team (distribution of Roles and Responsibilities, regular communication, systematic problem solving, goals /key indicators, regular monitoring of indicators /inconsistencies, work boards);
    • Kanban – increased productivity by more than 25% due to the introduction of a pull System;
    • VSM: - increase productivity, reduce intermediate stocks and optimize resources;
    • Red Corner / FMEA / ISPC / Poka-Yoke – reducing the level of defects / complaints;
    • Risk Assessment – reducing the likelihood of adverse events (security incidents, operator errors, etc.);
  • Conducting training on the elements of Lean manufacturing:
    • Lean Manufacturing – Lean Manufacturing;
    • Production System – Production System;
    • Visual Factory – Exemplary production;
    • 5S – The company's Production Process Management System;
    • Standardization – Standardization;
    • Kaizen – Kaizen Continuous Improvement System;
    • TPM (Total Productive Maintenance) – Universal Equipment Maintenance;
    • SMED (Single-Minute Exchange of Die) – Quick Conversion;
    • Poka-Yoke / Error Proofing – Error Protection;
    • Yamazumy / Work Balance Board – Work Balance Board;
    • Red Corner – Red Corner (Quality);
    • Kamishibai – Level Audit;
    • Working Groups – Working Groups;
    • Team Board – Team boards;
    • Leadership – Leadership;
    • KPI – Key indicators;
    • Kanban – Kanban Pulling System;
    • VSM (Value Stream Map) – Value Stream Creation Map;
    • FMEA (Failure Mode and Effects Analysis) – Analysis of the types and consequences of failures;
    • ISPC (In Station Process Control) – Process control at the Workplace;
    • Risk Assessment – Risk Assessment.

Get a personalized offer in a few clicks!

CRM-форма появится здесь
Cookie-файлы
Настройка cookie-файлов
Детальная информация о целях обработки данных и поставщиках, которые мы используем на наших сайтах
Аналитические Cookie-файлы Отключить все
Технические Cookie-файлы
Другие Cookie-файлы
Мы используем файлы Cookie для улучшения работы, персонализации и повышения удобства пользования нашим сайтом. Продолжая посещать сайт, вы соглашаетесь на использование нами файлов Cookie. Подробнее о нашей политике в отношении Cookie.
Настроить Принять все
Cookies