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MANUFACTURING
Toyota Production
System & Lean Manufacturing
Toyota started it all when it devised
the simplest and most efficient production system in the world. Now
everyone's doing it - under the banner of Lean Manufacturing. The concepts
behind the system are applicable to all manufacturers. Muda (operational
waste) elimination, zero inventories, rapid response, perfect quality, 100%
DIFOT and employee participation are the key concepts. Optim has vast
experience in training and implementing of Lean Enterprise solutions. Our
Beyond The Black Hole (Principles and Practices of Lean Manufacturing)
process is the obvious starting point for companies wishing to attack the
muda quickly and across the board. From here we can provide full support
and guidance as your company goes down the path of becoming a Lean
Enterprise.
At the operational level, Optim can support a Lean Manufacturing
implementation process with a complete range of educational programs and
improvement processes. Our Customer Focused Manufacturing process is
specifically designed to help manufacturing people understand Lean concepts
as applied to the factory, including customer focus, push/pull,
batch-and-queue, lead-time reduction, cellular design and the total impact
of waste on business performance. Our Blitzing The Value Stream process
applies similar principles to the administrative and support functions of a
manufacturing company as part of the same strategy - to gain very high
service levels at much lower costs to the business.
Layout & Flow Optimisation
Factory and warehouse layouts need frequent fine-tuning. Re designing your
layout may not seem a priority but some World-Class companies actually
measure their progress by how many times equipment is moved in a year. Poor
flow and under-utilisation of floor space costs companies dearly. Poor
layout is the root cause of many productivity, quality, OHS and
communication problems. Optim can help you design a new plant layout. Also,
through processes such as our Lead Time Blitz, Workplace Redesign and 5S
And The Visual Workplace, we can help your people to change the scenery,
accelerate material flow and improve customer service in an existing
facility.
Changeover Reduction &
Flexibility Improvement
Flexibility to meet the increasing diversity and variety of market demand
is a challenge most companies are experiencing. The explosion of demand for
new products is seriously eroding plant efficiencies. A key to remaining
viable is to increase flexibility whilst reducing manufactured costs. This
can be achieved through Optim's highly successful changeover reduction
programs. We use the creativity of your employees to reduce
changeover/setup/make-ready times dramatically in conjunction with Optim's
unique low cost methodology. Added bonuses are guarantees of motivation,
high people involvement and fast, tangible gains. See our Smart Changeovers
and our Smart Changeovers Blitz processes.
Kanban Implementation
Kanban is one of the simplest visual systems ever devised to control
production flow, inventory and manage the elimination of waste. However,
good implementations are uncommon because essential issues are
misunderstood or overlooked. Optim offers the best hands-on kanban training
and support processes in Australia (see Kanban
Basics and Kanban Masters). We educate employees in the principles, the
functions, the theory and the practice and we can provide support through
the implementation stages.
Mistake Proofing
Operator mistakes are facts of life but can be severely reduced both in
number and in effect. Mistake proofing, or Poka-Yoke, is a simple process
which draws on people ingenuity and experience to design simple and
practical ideas to reduce the occurrence of errors. The process utilises
visual controls and simple error avoidance concepts.
Process Simulation &
Automation
"Visualisation is the key to enlightenment".
Optim has had experience in Europe, North America and
Australia/New Zealand in the application of computer based simulation
techniques to optimise manufacturing and service industry processes.
Simulation allows low cost trials to be carried out before full
implementation takes place.
Automation opportunities are often overlooked. Optim can provide the
service to help you identify automation opportunities, evaluate them and
prepare capital justifications with projected paybacks etc.
Process Variability Reduction
& Capability Improvement
Variability is a fact of life and a fact of business. But customers hate
variability! High product or process variability means poor quality, low
yields and inflated costs. Optim can show your people simple ways to
measure, control and reduce variability. Using programs such as our
Statistics Sucks and Statistical Process Control, your people can learn by
our methods which are designed to remove the mystique and boring nature of
traditional statistical teaching.
Capability measures are a simple way to show how good or bad your process
is at meeting specification. Our process called Process Capability &
Variability Reduction will help your people to understand the capability
concept, measure process capability and develop strategies to improve your
process capability.
Process Standardisation
Our unique Work centre Improvement process helps employees get the best
from process equipment. They identify the critical-to-quality outputs as
defined by the customers and agree on the inputs and skills required to
achieve them. They produce their own work instructions, decision rules and
monitoring procedures to ensure those critical-to-quality outputs are
maintained, irrespective of who is running the line.
Many companies have recognised that lessons can be learned from others.
These may be non-competitors or other divisions within the same company.
Optim's Benchmarking process is different to conventional benchmarking. It
is a highly focused project oriented attack on waste elimination and draws
on the skills of operational people and their leaders who are brought
together from different work centres to tackle a common problem.
TOP OF PAGE
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Optim Pty. Ltd
Suite 3, 5-7 Chandler Rd
Boronia VIC 3155
Tel: +61 3 97620043 Fax: +61 3 97620071
Email: info@optim.com.au
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