Our services are based on the "Toyota way" continuous improvement system - Lean Manufacturing & Management

HOW TO OPTIMIZE YOUR COMPANY?
4 QUESTIONS - 4 ANSWERS

1. How to increase the plant size without adding new square footage?
2. How to reduce your production cost without increasing the employee's workload?
3. How to diversify your product offering without increasing your inventory?
4. How to give your employee's the will to take charge?



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1. HOW TO INCREASE THE PLANT SIZE WITHOUT ADDING NEW SQUARE FOOTAGE?

  • Our factories are too big even though we are missing space!
  • For this, we need to optimize our actual space and floor availability.
  • We need to grow our space internally!
  • In order to optimize the actual available space we need to :
    • reduce the work in progress inventory by reducing the batch size to be produced;
    • reduce the processing delay of an order by optimizing the layout into cells;
    • optimize the bottleneck in order to maximise the flow and production capacity;
    • refit with 5S the plant to maximise the space used;
    • control the inventory levels of direct material, wip and finished goods.

The goal of the use of these techniques is to maximize space and the production process efficiency.


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2. HOW TO REDUCE YOUR PRODUCTION COST WITHOUT INCREASING THE EMPLOYEE'S WORKLOAD?

We ask the employees to work at there normal capacity. Without working faster and harder, we can increase there efficiency by improving the process and there working environment.

We need to:


  • reduce non value added tasks;
  • eliminate waste;
  • optimize and manage the bottlenecks;
  • redefine new more efficient processes;
  • maximise the utilization of the equipments;
  • refit the working areas with 5S methodology.

Your employees will become more efficient without working harder and living in a better and more secure environment.


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3. HOW TO DIVERSIFY YOUR PRODUCT OFFERING WITHOUT INCREASING YOUR INVENTORY?

To be able to offer a greater product or service variety while optimizing your processes, you need to:


  • reduce the setup time of your machines our your administrative jobs;
  • reduce your batch size;
  • Bring closer together your work stations.

As an example, by reducing the setup time by 50% you can reduce your batch size by 50% and produce in the same time twice as many products or administrative jobs instead of one. At the end, your work in process inventory and finished goods will have been cut down and your turning rate up. You will be able to produce more regularly your high demand goods and the other ones will stay a shorter period in your warehouse. It is tame logic for general and healthcare services.


Even with a greater number of products or services, you will control more easily your inventory and you delivery time will be shorter.


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4. HOW TO GIVE YOUR EMPLOYEE'S THE WILL TO TAKE CHARGE?

  • Traditionally, employees were never heard to what they had to input and were never able to participate in the company's improvement.
  • The suggestions box, progress groups and reengineering groups never worked because they were imposing on workers.
  • The Toyota Way and Lean philosophy encourages the employee's participation and implication in the overall corporate improvement.
  • The employee's are the experts in what they do, so there fore, they are the best positioned assets to be part of the multidisciplinary team to improve the firm.

Your employees will be very proud to participate in the corporation's development.





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