Improving the quality of processes and maintaining acceptable levels of performance quality are important factors in the success of the company. A variety of methodologies are available for process improvement and Innovation. These include Six Sigma, Lean Management, Lean Six Sigma, Agile Management, Re-engineering, Total Quality Management, Just-In-Time, Kaizen, Hoshin Planning, Poka-Yoke, Design of Experiments, and Process Excellence. We chose and implement what is right for our customers.
Processes and Layout
Is the design helpful for a decent progression of materials? Are processes as connected as the current state of technology allows? Can certain tasks be semi-automated or automated without reducing the flexibility of your line? Are the operators well trained and do they have clear work instructions? Are the line leaders and the supervisors doing the right job?
We help bring in the engineering muscle you need to make quick progress without significant investment.
We work on solutions to remove the bottleneck from your business to take it to the next level using systems and tools. These lean tools and techniques have allowed typical factories to increase their efficiency by 20-60%. One critical indicator we look at is value-added time. We often get operators from 3-6 seconds per minute to 20 seconds or more — it means the time they spend transforming the product is multiplied by a factor of three or more. This can realistically be achieved with a 6-month lean improvement project & process innovation.
Predictive & Preventive Maintenance
Most manufacturers see automation as the solution to rising manpower costs. We have seen multiple instances of a factory buying robots and not being able to maintain them properly. A poorly set piece of complex equipment can run a factory out of business through a combination of downtime and out of cash quality of products produced.
The concepts of predictive and preventive maintenance are new to most of the manufacturing leaders. They usually fix machines after having breakdown. This approach must change before the factory goes down the path of automation.
Your line operators, line leaders, supervisors, executives, and engineers have a lot of good ideas. They know your processes very well — much better than the managers or any external consultants you bring in. Giving them some introductory training modules, such as the seven wastes, can help you tap into their ideas, and in turn, help you save a lot of money.