Productivity

(for Office too)

5S is just about cleaning up and housekeeping, isn’t it? Isn’t 5S just basic common sense? We’re too busy for 5S; can’t we start the Lean implementation in another way? How does 5S compare to 3S and 6S?

Do you need to start stabilizing your processes? Is a Visual Workplace one of your goals? Do you want to reinvigorate previous 5S efforts?

This Lean workshop trains employees on the principles of 5S. Classroom instruction alternates with shop floor exercises to identify opportunities for 5S. Participants learn why 5S needs to be the starting point in their Lean Efforts, how it contributes to stabilizing their processes, what forms of resistance to 5S are commonplace, and how to get started. The tools to implement 5S and the monitoring systems are presented. Lean Programs are continuous improvement processes and the 5S system gets the improvement process started.

5S Topics covered:

  • 5S Background Information
  • 5S Pillars: Sort (Seiri), Set in Order (Seiton), Shine (Seiso), Standardize (Seiketsu), Sustain (Shitsuke)
  • Common Types of Resistance
  • 5S Techniques: Red Flagging; Organization; Visual Methods; Prevention
  • Principles of Motion Economy
  • The “Unbreakable” Concept of Prevention Techniques
  • Principle of Incorporation
  • Use Elimination
  • Examples and Exercises

5S Practical video presentation: 5S Factory Makeover and Visual Control

This 2-5 days session is for 15 – 20 participants and is suitable for a diverse audience: Production, Employees, Technical, Supervisory, and Managerial Personnel. Due to the field exercises, this workshop is best held on-site where participants can easily observe the production process.

(for Office too)

Are you looking to utilize Kaizen Events in your Lean Implementation? Would you like to have your team guided through the process?

Kaizen Events can be as short as one-day Kaizen Blitz or a two- to five-day event. If this is the first event for the majority of the participants, a minimum of a four- or five-day event should be planned. This allows time to review key Lean Principles and tools that are expected to be used during the course of the event along with more time to experiment with some of the counter-intuitive Lean concepts.

Exegens® facilitates this entire process and provides the training. Your organization designates a Team Leader who co-ordinates the effort with our assistance. By then end of the event, they are truly leading the activity and everyone has learned the mechanics of the process. Participants receive guidebooks that contain the instructional information presented to keep for future reference.

Kaizen – Practical video presentation: Breakthrough Kaizen Events

Typical Kaizen Event – secquence of events:

  • Day 1 (1st half) – Kaizen Event introductory training & refresher of key Lean concepts.
  • Day 1 (2nd half) & Day 2 – Collect current state data & document. Develop current state Value Stream Map (VSM).
  • Day 3 – Determine desired future state, identify opportunities for improvement, brainstorm solutions, and test selected solutions. Make changes to actual process.
  • Day 4 – Prepare management presentation. Document changes (Standard Work, Assembly Instructions, ISO documents, etc.) Train personnel on the new process. Deliver management presentation.

Pre-requisite: All participants should have familiarity with Lean concepts such as are covered in the Lean Simulation Workshop.

This four day session is for 8 – 15 participants and is suitable for a diverse audience: Production Employees, Technical, Supervisory, and Managerial Personnel. Most participants should be personnel who perform day-to-day actual production activities. This workshop must be held on-site.

(for Office too)

Are you spending money on things that do not contribute value for the customer? Do your customers return products that are defective? Do you fail to have product that the customer wants to buy, yet have excessive inventories of items that aren’t selling? Are your employees waiting on upstream processes before than can perform their work? Are your employees searching for the tools, equipment, and information that they need to do their jobs? Does product build up in large quantities before it is handled? Do you transport product excessively?

Producing anything that the customer doesn’t want or need is a waste. It lowers your profits. It leaves you less competitive in your market.

This one day Lean workshop trains employees on the principles of the Eight Wastes. It helps them to see the waste that is hidden or that is taken for granted and it provides them with tools to first reduce, and then eliminate waste from their processes.

The eight wastes or “muda” are described, examples are provided, and the impact of reducing or eliminating these wastes is presented. Exercises give the participants practical knowledge. Prior to implementing Lean Techniques, manufacturing processes typically have as much as 95% of their cycle time associated with these eight wastes. Utilizing the Lean techniques discussed in this workshop can help to dramatically reduce these wastes and their associated costs.

8 Wastes Topics covered:

  • Lean Principles Background Information
  • Value Added and Non-Value Added Activities
  • 8 Wastes – Identification and Discussion (Overproduction, Waiting, Excess Inventory, Transportation, Motion, Overprocessing, Defects, Human Talent)
  • Lean Improvement Tools
  • Lean Methods: Cellular/ Flow Manufacturing, Push/ Pull Systems, Total Productive Maintenance, Value Stream Mapping
  • Exercises

Lean Practical video presentation: What Lean means? 

This one day session is for 15 – 20 participants and is suitable for a diverse audience: Production Employees, Technical, Supervisory, and Managerial Personnel. Due to the field exercises, this workshop is best held on-site where participants can easily observe and analyze your product processes.

Achieving continuous flow is the ultimate objective of lean production.

Where do you begin? What type of analysis is needed to start developing flow? How do you balance the pacemaker process? What is needed from upstream processes to support the pacemaker? What information flows are needed? How should the process be monitored?

This one-day workshop concentrates on the technical details required to achieve continuous product flow. It is concerned with the analysis of existing processes, the selection of products to include in a workcell, and the design and layout of the workcell. It continues with addressing the information flows and upstream material flow requirements. This is an interactive course that will give you essential information in how to achieve continuous flow in your production operation.

Continuous Flow Topics covered:

  • Analysis of existing processes
  • Product-Quantity (PQ) Analysis
  • Bill of Material review
  • Takt time and capacity
  • Collecting assembly time data
  • Line balancing
  • Assembly station design
  • Part presentation
  • Conveyance systems and concepts
  • Plan for Every Part (PFEP)
  • Delivery route
  • Point of Use Storage
  • Heijunka box
  • Managing low-volume high-mix requirements

LEAN Practical video presentation: Single Piece Flow

This Lean workshop trains 15 – 20 participants and is suitable for a diverse audience: Production Employees, Technical, Supervisory, and Managerial Personnel.

(for Office too)

This one-day workshop demonstrates the principles and concepts of Lean Manufacturing through lectures and multiple hands-on simulations. It is also intended to provide management staff and employees at all levels of your organization with a basic understanding of Lean Implementation, and the benefits to be gained.

Instruction is provided on the following topics:

  • Lean Manufacturing – An overview of this methodology (also known as “The Toyota Production System”) along with a description of its origin, case studies of recent implementations, and how it fits into today’s management techniques.
  • Eight Wastes – The eight wastes or “muda” are described, examples are provided, and the impact of reducing or eliminating these wastes is presented. Prior to implementing Lean Techniques, manufacturing processes typically have about 95% of their cycle time associated with these eight wastes.
  • Poka-Yoke – The technique of “poka-yoke” or mistake-proofing is discussed and examples of successful implementations are presented.
  • Process Quality – The natural outgrowth of improved product quality, with First Pass Yields approaching 100%, as a result of eliminating the seven wastes, implementing poka-yoke, and achieving one-piece flow (batch size reduction) is explained.
  • 5S – A description of how the five Japanese activities utilized in maintaining a clean and manageable work area can be implemented: Seiri, Seiton, Seiso, Seiketsu and Shitsuke.
    Plant Layouts – Facility layouts that are conducive to supporting one-piece flow and Lean Manufacturing techniques are discussed.
  • Non-Value Added Activities – The differentiation between Value Added and Non-Value Added activities is described. Also, the difference between essential and non-essential Non-Value Added activities is raised as a topic for discussion.
  • Batch Size Reduction –The logic behind this counter-intuitive manufacturing technique is presented – along with the ultimate goal of achieving one-piece flow.
  • Quick Changeover – The impact of utilizing the Single Minute Exchange of Dies (SMED) concepts to achieve dramatically quicker changeovers which enable reduced cycle times and reduced batch sizes is presented.
  • Point of Use Storage (POUS) – How Point of Use Storage can streamline manufacturing processes and support one-piece flow.
  • Kanbans – The Kanban technique, which constitutes a type of visual signal, is discussed along with the concept of a “pull” system.
  • Total Productive Maintenance (TPM) – The role that Preventative and Predictive Maintenance concepts play in reducing wastes and lowering cycle times is discussed.
  • Value Stream Mapping (VSM) – The process diagramming method known as Value Stream Mapping which depicts both process and information flows is presented.

LEAN Practical video presentation: Building a Lean Culture, Kanban Systems, VSM and Introduction to Lean Manufacturing

This course is designed for 15 – 20 participants and is suitable for a diverse audience including production, engineering, quality control, supervisory, and management personnel.

Zero Defects sounds like just a “slogan” – can we really achieve it? Is it true that most Poka-Yoke methods are developed by Production personnel instead of Engineers? 100% inspections doesn’t sound realistic, do they provide any real benefit?

Zero Quality Control (ZQC) is based on the principle that defects are prevented by controlling the performance of a process so that it cannot produce defects – even when mistakes are made. ZQC utilizes source inspections, 100 percent inspections, immediate feedback and poka-yoke devices.

The objective is to detect errors before they actually can cause defects thus preventing the defect from ever happening. Because most Poka-Yoke devices are common-sense practical devices actually developed by production line workers, it is most informative to review and discuss actual ideas that have been developed and are in use. Accordingly, while this course does provide traditional instruction on the concepts for Poka-Yokeing a process, it presents a wealth of actual examples to get your team’s creative processes moving!
This one-day course is an excellent way to begin your Poka-Yoke efforts. Classroom instruction alternates with shop floor exercises to identify and apply the lessons learned to practical shop floor situations. This is a highly interactive session where participants can actively enter into the discussion and learning process.

Poka-Yoke topics covered – The Five Elements & Structure of Production:

  • Common Causes of Defects
  • Zero Concept and Zero Quality Control
  • Comparison of Zero Quality Control and Statistical Quality Control
  • Judgment, Informative and Source Inspections
  • Successive and Self-Check Systems
  • Poka-Yoke Systems: Regulatory Functions, Setting Functions
  • Detecting Errors Before They Cause Defects
  • Detection Measures for Poka-Yoke Systems
  • Examples of Poka-Yoke Systems
  • Applying What You Have Learned

Poka-Yoke practical video presentation: Mistake Proofing (Poka-Yoke)

This Lean workshop can include up to 20 participants and is suitable for a diverse audience: Production Employees, Technical, Supervisory, and Managerial Personnel. Due to the field exercises, this workshop is best held on-site where participants can easily observe the production process.

Workshop Setup Reduction

You are started down the path of a Lean Implementation. Your 5S program is running very smoothly. Processes have been stabilized. Congratulations are due on your accomplishments!

Now you want to get away from batch processing and move to a true flow production system. Most likely, setups are one of the key reasons for making large batches, so setup reduction is the next phase. While there maybe significant challenges, setup reduction will normally create some of your biggest gains in going Lean. And, the teams that work on this process find it to be extremely rewarding. This is where they most likely hit a home run!

Is it time to get your team prepared for the challenge? How do they get started? What do they look for? Can we give them some ideas?

This one-day course is an excellent way to get your team initiated and on track. Classroom instruction alternates with shop floor exercises to identify and apply the lessons learned to a practical setup reduction situation. Techniques for setup reduction will be presented along with examples through case studies of actual applications.

SMED Topics covered:

  • Background Information on moving from Batching to Flow processes
  • Two Types of Setup Activities: internal setup, external setup
  • Basic Steps in Setup Process
  • Stages of Setup Improvement: separating internal and external setup, converting internal to external setup, streamlining the setup operation
  • Techniques for Applying SMED: advance preparations, function standardization, implementation of parallel operations, elimination of adjustments, mechanization, standardizing setups
  • Examples and Case Studies from site

SMED Practical video presentation: Quick Changeover for Lean Manufacturing

This Lean workshop can include up to 20 participants and is suitable for a diverse audience: Production Employees, Technical, Supervisory, and Managerial Personnel. Due to the field exercises, this workshop is best held on-site where participants can easily observe the production process.

(for Office too)

Does your organization experience some problems that have been ”solved” but yet they continue to plague everyone by reoccurring again and again? Each time, we think that the problem has finally been resolved only to find out that it hasn’t. What’s happening, of course, is that we are addressing the symptoms instead of the root cause.

What techniques are available to improve your problem solving efforts? What are the quick methods to handle ”easy” problems? What can we use for the more difficult problems?

This interactive workshop will provide you with a set of root cause analysis and problem solving techniques to enable you to systematically tackle challenging and long standing problems.

Workshop Outline

The first session provides instruction on RCA techniques and concepts. The second session (optional) provides participants with the opportunity to present to the group how they applied the techniques to solve a problem in their area.

Session One (one-day)

  • Problem Definition and Root Cause Analysis
  • 5 Whys and Types of Causes – Presumptive – Contributing – Root
  • Causal Factors
  • Cause/Effect Diagramming – Fishbone (Ishikawa) Diagram
  • Logic Cause/Effect Diagrams – TOC & Apollo Root Cause (Categories of Reservation, Necessary Condition, Assumptions)
  • Change Analysis
  • Control Barrier Analysis
  • Event and Causal Factor Charting
  • Risk Analysis – Failure Mode Effect Analysis (FMEA)
  • Fault Tree Analysis
  • Overview of Problem Solving Methods
  • Seven Step Method
  • Eight Disciplines (8 D)
  • Plan-Do-Check-Act (PDCA)
  • Define-Measure-Analyze-Improve-Control (DMAIC)
  • TOC Thinking Processes
  • Selection and assignment of problem for analysis.

Session Two (half-day) – optional

Participant Presentations – each participant will describe to the group, the root causes that they identified for their selected problems and the techniques they used.

Root Cause Analysis Practical video presentation: Supply Chain Management

This workshop is for up to 20 participants and is suitable for anyone who needs to solve problems including: production, maintenance, quality, technical, office area and engineering personnel.

Is your production interrupted by unplanned equipment breakdowns? Do you have to run machines slower to handle “difficult” materials? Do operators struggle with erratic or poorly performing equipment? Is your equipment one of the causes for poor product quality?

If you have automated processes that are causing a lack of process stability, then Total Productive Maintenance is the solution! Through TPM, you:

  • Reduce unplanned equipment breakdowns
  • Increase equipment operating uptime
  • Improve equipment reliability
  • Increase equipment performance
  • Identify equipment deterioration sooner to prevent quality defects
  • Reduce or eliminate setup and adjustment time
  • Reduce yield losses caused by unused or wasted raw materials

Do you want to improve production process stability? Would a TPM program benefit your organization? This one-day workshop is an excellent way to evaluate and get your organization started on a TPM effort. Classroom instruction alternates with shop floor exercises to identify and apply the lessons learned to a practical setup reduction situation. Techniques for setup reduction will be presented along with examples through case studies of actual applications. This is a highly interactive session where participants can actively enter into the discussion and learning process.

Total Productive Maintenance (TPM) Topics covered:

  • Background on TPM
  • Zero Concept – Zero Accidents, Zero Defects, Zero Breakdowns
  • Improving PQDSM
  • Understanding Losses (types of losses, 8 Big Losses)
  • Six Major TPM Activities and the Five Countermeasures
  • Autonomous Maintenance
  • TPM Program (7 steps, 3 stages of development, PDCA Cycle, work procedures and standards)
  • Overall Equipment Effectiveness (OEE)
  • Maintaining the TPM Program

TPM Practical video presentation: TPM – Total Productive Maintenance

This lean workshop can include up to 20 participants and is suitable for a diverse audience: Production Employees, Technical, Supervisory, and Managerial Personnel. Due to the field exercises, this workshop is best held on-site where participants can easily observe the production process.

(for Office too)

Have you visualized the value streams in your organization? Can everyone ”see” how value is provided to your customers? Where is your constraint (pacemaker process)? What information do people in the value stream need to perform their jobs? Have you identified opportunities for improvement? Does everyone know what those opportunities are?

Communication throughout the organization can be difficult. Value Stream Mapping is the visual way to communicate. It gets everyone on the same page. This workshop will familiarize your employees with the Value Stream Mapping (VSM) technique. At the end of the workshop, participants will have developed a Current State VSM for one of their processes. Classroom sections alternate with field exercises to provide experience in applying the methodology to a practical situation. This technique documents:

The Value Stream for an entire Product or Product Family

  • Essential Product Activities
  • Necessary Information Flows
  • Key Process Data (Cycle Times, Setup Times, etc.)
  • Identification of Value Added & Non-Value Added activities.

Value Stream Mapping Topics covered:

  • VSM Background Information
  • Objectives
  • Choose the Value Stream from site
  • Map the Current State
  • Identify Lean Metrics
  • Map the Future State
  • Costumer Demand
  • Continuous Flow
  • Levelling
  • Create Kaizen Plans
  • Implement Kaizen Plans
  • Value Stream Managers

VSM Practical video presentation: Mapping Your Value Stream

This Lean workshop trains 15 – 20 participants and is suitable for a diverse audience: Production Employees, Technical, Supervisory, and Managerial Personnel. Due to the field exercises, this workshop is best held on-site where participants can easily observe the processes to be mapped.

Controlling

În ultima perioadă, instrumentele și procedurile de lucru ale construcției bugetare și de costuri pe produse/activități par că nu vă mai ascultă? Simțiți nevoia unui sistem de Controlling confortabil de utilizat?

În ziua de azi, proiectarea, implementarea și îmbunătățirea sistemului de CONTROLLING reprezintă o prioritate pentru multe organizații. Controlling-ul furnizează date pentru diferite scopuri, inclusiv planificarea, controlul bugetar și calculația de cost. Managerii de la toate nivelele afacerilor – în servicii și în producții industriale- sunt clienții informațiilor contabile. Deciziile fundamentate au rădăcini in Controlling.

Esența controlului este compararea performanțelor planificate sau țintă. Monitorizarea proceselor și compararea cu variația descoperită a țintelor din planul original (activitatea de control), variații care pot fi utilizate ca ghid al activităților corectoare a planului original, sau, dacă monitorizarea actualelor rezultate și condiții se petrece într-un mediu incert, se poate revizui planul original. Controlul are o mare importanță strategică și este partea planului general revizuit mai ales în condiții de afaceri volatile, condiții de incertitudine. Planificarea și controlul sunt activități distincte, dar ele merg mână în mână. Pentru maximizarea beneficiilor planificate (bugetate), managerii ar trebui să utilizeze acest plan cum ar fi benchmark pentru controlling (evaluarea efectivă și eficienta a implementărilor). În mod contrar, este dificil de controlat activități fără un plan benchmark.

Obiectivul nostru este de vă ajuta să dezvoltați și să implementați proiectele Dumneavoastră, cum ar fi: stabilirea noului sistem informațional de raportare, proiectarea managementului rezultatului financiar (profit & pierdere), introducerea centrelor de profit și/sau cost în organizația Dumneavoastră și stabilirea proiectelor de management și controlling. Mai mult, noi putem asigura companiei Dumneavoastră asistență și coaching în planificarea bugetară și strategică.

EXEGENS® a dezvoltat un program de reducere a costurilor care garantează reducerea semnificativă a costurilor unitare ale produselor și serviciilor din companii prin maximizarea eficacității și eficienței resurselor consumate.

Provocari

Reducerea costurilor si competitivitatea prin pret reprezinta o provocare continua pentru toate companiile, atat pentru viitoarele produse, cat mai ales pentru produsele deja existente. Un sistem performant de CONTROLLING, presupune cunoasterea si imbunatatirea continua a costurilor, indiferent daca sunteti companie mare sau mica, de productie, de servicii, de comert, sau de distributie.

Noutatile principale prezentate in acest training (concepte Exegens®):
  • Manufacturing Cost Policy Deployment (MCPD);
  • Daily Cost Management (DCM);
  • Annual Manufacturing Improvement Budgets (AMIB);
  • Annual Manufacturing Cash Improvement Budget (AMCIB);
  • Waste Elasticity of Losses (WEL).
Solutii

Pentru a supravietui pe pietele cu o competitivitate mare si pentru a realiza un profit rezonabil, Exegens® oferă companiilor o abordare sistemică și sistematică a cunoașterii și îmbunătățirii costurilor prin:

  • abordarea costurilor pentru fiecare familie de produse in parte;
  • determinarea nivelului costului unitar curent;
  • stabilirea tintelor de imbunatatire continua a costurilor in functie de semnalele pietei;
  • identificarea oportunităților și a mijloacelor de indeplinire a tintelor costurilor în funcție de losses/waste din procese;
  • dezvoltarea, implementarea și monitorizarea planurilor de imbunatatire continuă a a costurilor.

Detalii…

Etapa I: Controlling Audit – analiza tehnicilor și metodelor utilizate în mod curent în firma Dumneavoastră vs. analiza tehnicilor și metodelor utile de a se implementa.

Etapa a II-a: Curs Controlling. Profitabilitatea afacerilor – transmiterea informațiilor privind Controlling-ul necesare a fi însușite de utilizatorii din firma Dumneavoastră pentru analiza si implementarea noilor proceduri.

Etapa a III-a: Coaching & Implementing – Implementarea tehnicilor și metodelor în funcție de profilul firmei Dumneavoastră.

Obiectivul nostru este de vă ajuta să dezvoltați și să implementați proiectele Dumneavoastră, cum ar fi: stabilirea noului sistem informațional de raportare, proiectarea managementului rezultatului financiar (profit & pierdere), introducerea centrelor de profit și/sau cost în organizația Dumneavoastră și stabilirea proiectelor de management și controlling.

Mai mult, noi vă putem asigura companiei Dumneavoastră asistență și coaching în planificarea bugetară și strategică.

Detalii…

Contact us to learn more about how we can help your organization with our consulting and our open/in house training services.