Some of our projects include in excess of c £2.5 Million for creating value stream that transformed manufacturing processes. The objectives were lead time reduction of manufactured products , increase in profitability by more than 40%.
Developing strategies for Value Stream Linkage that required a structured approach to analyze the current state, identify bottlenecks, and design a future state that aligns with business objectives. Here’s a step-by-step guide to assist set up an ideal state.
In this project our approach was as follows:
1
Define Objectives and Scope
- Clarify goals: Are you focusing on reducing lead times, lowering costs, or increasing throughput?
- Set boundaries: Identify the start and end points of the value stream.
- Engage stakeholders: Include input from cross-functional teams to ensure alignment and buy-in.
2
Map the Current State
- Visualize the process: Use tools like Value Stream Mapping (VSM) to map the flow of materials and information.
- Identify metrics: Focus on key performance indicators (KPIs) such as lead time, cycle time, and inventory levels.
- Pinpoint waste: Look for bottlenecks, excessive inventory, or redundant processes (aligned with Lean’s 8 wastes: TIMWOOD).
3
Analyze Gaps and Opportunities
- Root cause analysis: Use techniques like the 5 Whys or Fishbone Diagram to understand issues causing inefficiencies.
- Quantify impacts: Assign values to problems (e.g., how much time or cost could be saved by eliminating a bottleneck).
4
Design the Future State
- Streamline flow: Focus on creating a smooth, uninterrupted flow of materials and information.
- Link processes: Reduce handoffs and integrate steps where possible.
- Implement pull systems: Shift from push to pull systems, aligning production with customer demand.
5
Leverage Technology and Automation
- Digital tools: Implement ERP/MMS systems to improve real-time communication and process control.
- Flexible machinery setup: Standardize and optimize machinery to support rapid changeovers and minimize downtime.
6
Align with Lean Tools and Techniques
- SMED (Single-Minute Exchange of Dies): Reduce setup times to improve flexibility and responsiveness.
- Kanban: Control WIP and maintain consistent flow.
- Heijunka: Level production to meet customer demand efficiently.
7
Pilot the Plan
- Test small: Run the linkage plan in a single department or a small section of the value stream.
- Monitor closely: Track metrics before and after implementation to gauge effectiveness.
8
Implement and Sustain
- Roll out systematically: Scale the approach across the organization in phases.
- Train employees: Ensure all team members understand and can execute their roles in the new system.
- Use PDCA cycles: Continuously refine the process using Plan-Do-Check-Act methodology.
9
Monitor and Improve
- Visual dashboards: Use KPIs to track performance.
- Feedback loops: Regularly collect input from operators and supervisors.
- Continuous training: Update skills as technologies and processes evolve.
10
Celebrate Success and Share Lessons learnt
- Highlight improvements in lead times, cost reductions, or customer satisfaction.
- Share the linkage strategies and lessons learned across other value streams.
Other projects involved:
Coaching and training factory shop floor associates in use of problem solving tools based on Toyota Production System (TPS) methodology. Certification of candidates in Lean six sigma Yellow and Green belts
Middle level management is implementing lean supply chain using Material Replenishment systems (Kanban) , Plan for Every Part (PFEP) for reducing inventory and Just in Time availability of machined and sub-assembled parts for assembly and despatch to customer.
Creating a lean Standard Work for Flow in a multi million pound turn-over plant that manufactures niche products for the rail and telecoms market.
Increasing Overall equipment effectiveness (OEE) of a rolling mill plant that produces cable tray for the electrical construction business .
Please contact us for specific requirement and we can help and assist you in meeting your requirements.