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Discrete manufacturinng
Value Stream Mapping

Value Stream Mapping wokshops allows to plan for implementation of Kanban, Heijunka, Supermarkets and other tools of the Pull System. Participants learn the tools during a simulation game that in a very realistic way illustrates techniques for calculating number of Kanbans, sizing of Supermarkets, designing a Pacemaker, etc. To strengthen the learning, participants also develop a Current and Future State Map for the onsite manufacturing process and create an action plan for implementation of improvements. 

To prepare for the workshop, a consultant will visit the site to help determine one product family which will be the subject of the exercise. 

Kaizen Blitz

A Kaizen Blitz process begins by choosing a manufacturing process, work cell or an area where improvements will be implemented. Next, a cross functional team composed of employees from many ranks is selected to participate in the workshop. 

Kaizen Blitz itself is 3 to 5 days long, depending on the complexity of the selected production area. The Workshop begins with intensive training that includes team building exercises and overview of Lean Manufacturing tools. Next, the team analyzes the current process and identifies inherent waste, brainstorms improvements, creates an action plan and immediately implements it in the work place. All changes are standardized to ensure they will be maintained. Typical results include increased productivity, improved quality, reduced work in process inventory, improved safety and other key process indicators. 

The Kaizen Blitz process ends with a 30 day follow up meeting during which the team reviews implemented changes and suggests future improvements.

Zero Quality Control

Only through the prism of quality can you achieve business objectives of each company: customer satisfaction and low costs. A company that prioritizes satisfying all needs of its customers is not able to guarantee the highest quality and low cost. Similarly, a company that tries to constantly reduce costs will cause quality of its products to suffer.

 

Prioritizing quality is a long-term strategy, which may cause a short term loss. However, it is the only strategy that ensures continuity of reputation and financial success.

 

Quality triangle

 

People and machines make mistakes, as a result of which defects may appear. Poka-Yoke prevents an error from occuring or a defect from entering a process. Examples of Poka-Yoke are present everywhere in our daily life, eg. a round manhole prevents its cover from dissapearing inside.

 

poka-yoke

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