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At Optim, we offer a wide range of programs, which have been individually
designed to fill the ongoing demands of industry standards. Below is a list
of the programs we offer and a description of what they include.
BENCHMARKING I BEYOND THE BLACK HOLE I BLITZING THE
VALUE STREAM I CUSTOMER FOCASED MANUFACTURING I 5S & THE VISUAL
WORKPLACE I HIGH
PERFORMANCE PEOPLE I KANBAN BASICS I KANBAN
MASTERS I LEAD-TIME BLITZ I MAKING SERIOUS CHANGE I MURDERING
THE MUDA I NEW
GENERATION PROBLEM SOLVING I NEW ROLES FOR SUPERVISORS I POKE-YOKE
I PROCESS CAPABILITY & VARIABILITY REDUCTION I SERVICE TO
PLEASE I SMART
CHANGEOVERS® I SMART CHANGEOVERS® BLITZ I STATISTICAL
PROCESS CONTROL I STATISTCS SUCKS I TEAM BUILDING I THE ILLS OF
INVENTORY I VALUE
ADDED MACHINES I VALUE ADDED PRODUCTIVITY ANALYSIS I VALUE
STREAM ANALYSIS I WORK-CENTRE
IMPROVEMENT I WORK PLACE RE-DESIGN
BENCHMARKING
This program represents a fresh, practical and highly effective way for
companies to exploit the benchmarking process. We work with senior
management to select a team of operational people, often from different divisions
or departments, who are given the task of achieving significant operational
economies.
We train the team in process measurement, data analysis, project
management, team-based problem solving techniques and benchmarking. We
guide the team through the early project stages until it has determined
"best practices" for recommendation and adoption through each
facility. The process can be applied internally within one site, across a
number of sites in one company or between 'partnering' companies.
BEYOND THE
BLACK HOLE
(The Principles and Practices of Lean Manufacturing)
The theme of this two-day workshop is service and productivity improvement
through Lean Manufacturing. The objective is to present to management and
employees a practical and proven roadmap for making sustainable and
significant change. We go through the actual process of transforming a
(simulated) typical manufacturing company that is constrained by narrow
thinking, departmental barriers and complex systems.
Step-by-step, we work through a series of techniques designed to radically
improve operational performance in production and administration. The
improvements are measured and the participants see and experience the
outcomes of the changes that they implement in the simulated company. The
simulated company starts out with a typical departmentalised structure. The
workshop ends with the operations reformed into a customer-focused business
unit, which meets all customer requirements in a fraction of the time, and
at a fraction of the cost.
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BLITZING THE
VALUE STREAM
Service, support and administrative efficiencies have always been difficult
to measure. Efforts to improve office productivity are usually
intra-departmental and ignore the needs of other departments or their
impact on the overall efficiency of the business. The end result is often
the introduction of new technologies that incorporate the waste, create
mountains of paper and add to the problem. In Optim's new Blitzing The
Value Stream program, we expose the unnecessary complexity that has evolved
within your own administrative processes.
Using simple concepts and tools, the participants progressively redesign
your information flow. Non-value adding activities are eliminated, response
times are reduced, systems are simplified and visibility is increased.
The outcome of this program is a redesigned workplace where skills and
responsibilities are shared and departmental barriers are demolished. But
perhaps the biggest benefit it offers is in the genuine opportunity it
provides for operational people to take an active part in improving their
own productivity and, by doing so, securing their own futures.
CUSTOMER
FOCASED MANUFACTURING
A factory simulation is used to make comparison between traditional
manufacturing typified by a functional layout and batch-and-queue
production driven by conventional 'push' scheduling, and contemporary
customer-focused 'pull' methodology.
This program brings together many of the concepts developed in other Optim
programs. The participants get to feel the benefits of working in a very
flexible company where all the employees are in touch with the customers
and where lean manufacturing has reduced costs and response times. In this
workshop, the participants get to see how all the main principles finally
come together.
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5S AND THE VISUAL
WORKPLACE
This workshop demonstrates the 5S process and facilitates the immediate
implementation of 5S principles in the work place. We work with the people
over two days to upgrade the orderliness and maintenance standards of their
workplaces. The objectives are to achieve a dramatic change in both the
appearance and the functionality and to set new and sustainable standards
for the future. This program is often the initiation of activities in the
workplace for a company, which has elected to pursue Lean Thinking.
Key objectives are:
· The elimination of unwanted/unused materials and equipment
· Efficient storage and control of equipment and stock at the workplace
· The implementation of visual controls
· The standardisation of 5S practices to maintain the new work place
standards.
HIGH PERFROMANCE
PEOPLE
Teamwork and team responsibilities are topical issues today. However,
rarely do we witness successful implementation, usually because of a lack
of understanding of important issues. High Performance People provides a
path for involvement by explaining the influence of the group on behavior,
motivation, attitudes and discipline, enabling real teamwork to be achieved
in a way that is truly participative and mutually beneficial.
This program emphasises the differences between empowerment and
involvement, explains the changing roles of people in the new organisation
and examines the roles of reward and motivation.
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KANBAN BASICS
Kanban is one of the most successful concepts ever devised to control
production flow and to manage the elimination of waste. However, good
kanban implementations are uncommon because essential issues are
misunderstood or overlooked. This Kanban Basic workshop introduces
operational people and their leaders to:
· the principles of customer focused manufacturing
· kanban functions, rules and types
· trigger, traffic light and heijunka boards
· kanban calculations
· kanban rules
· kanban implementation
KANBAN
MASTERS
The implementers and owners of a kanban system require in-depth knowledge
of the procedures for setting up and running a kanban system. This program
looks in detail at the various kanban and sequence board types and how they
are used. Time is taken to understand how the kanban formula works for
different scenarios and the participants learn to use Optim's kanban
'transition' spreadsheet. The implementation sequence is studied. We look
how kanban can be used as a continuous improvement tool and we establish
the disciplines that make the system work effectively.
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LEAD-TIME
BLITZ
We consider the key issues underpinning the competitive success of today's
business. We find that the important principles are not exclusive to the
Kerry Packers of the world but are, in fact, largely common sense.
The workshop takes us inside two competing companies where we are able to
make some interesting comparisons. We see through a simulation exactly what
it takes to dramatically improve the performance of the worst company to
make it World-Class.
Concepts include:
· Customer service
· Quick response
· Value adding vs. Cost Adding
· Waste elimination
· Process linking
· Cellular manufacturing
· Batch size reduction
MAKING SERIOUS
CHANGE
This one-day program is for Managers in both manufacturing and service
sector industries that want to involve their people directly in
productivity and service improvement. The workshop covers:
· Recognising the need for change
· The critical role of management
· Strategies for improvement
· Measuring corporate productivity
· People involvement
· Incentives
· Tools for change
· Resourcing change
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We address the issues of serious and sustainable change in business through
a sound framework of proven principles and practical tools. Participants
experience the use of simple techniques for process analysis and
improvement. They also develop their own plan for application of the principles
on return to their firms.
MURDERING
THE MUDA
An effective strategy for uniting the workforce is to focus everyone's
attention on a common enemy. In this short workshop, the participants are
introduced to the concept of operational waste (muda). They get to see how
extensive the waste is and what it is costing the business. We measure the
waste using Optim's waste audits and we consider how it might be reduced.
The objective is to create a culture amongst the workforce that is obsessed
by waste and with its elimination.
NEW GENERATION
PROBLEM SOLVING
The "New Generation Problem Solving" course combines teambuilding
with creative problem solving techniques and statistical analysis. The
participants understand the interdependence of the three elements for
success. They experience the satisfaction of a total approach to problem
solving. Also, they learn that by working together using basic techniques
for data collection and effective team interaction, they can achieve
results beyond their own expectations.
Topics covered include: personal influences, setting goals, decision
making, creative problem solving, data collection and analysis, project
management.
At the conclusion of the workshop the attendees are required to plan and
manage a real problem-solving project. At the conclusion of the project
they are expected to produce a short report and give a presentation to
management and colleagues.
This course has produced some stunning results for a number of Optim's
clients. These include massive reductions in product loss, resource waste
and manufactured cost with significant improvements in culture and morale.
This course is an optional module for the Leadership ll Certificate -
a Frontline Management Course.
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NEW ROLES FOR
SUPERVISORS
The supervisor's role is changing as companies move down the path of
greater autonomy for middle management and supervision. As roles change,
many supervisors feel threatened as subordinates become involved in
continuous improvement and change. Supervisors are expected to be leaders
and facilitators but in many cases do not have the understanding or skills
to effectively fulfil the expectations made of them.
This program covers essential topics that must be understood by supervisors
before they can feel they have a worthwhile role to play in an environment
that needs leaders. This program is designed to be run in stages over a
three monthly period of time, so allowing each element of the training to
be given time for practical application.
POKA-YOKE
(Mistake Proofing)
Poka-Yoke is a process for addressing mistakes and random failures that
occur in every workplace in industry, offices, hospitals, shops and
government departments. This short workshop teaches the basic concepts
behind Poka-Yoke and the reasons why Poka-Yoke is important to industry.
Attendees are given the opportunity to analyse their own equipment for
Poka-Yoke applications. Projects are then initiated to apply their ideas
back in the workplace.
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PROCESS
CAPABILITY & VARIABILITY REDUCTION
Statistics and measurement lectures were designed by academics to blind,
baffle and bore their pupils into submission. Yet the old adage says,
"You can't control what you don't measure." Optim has made a
breakthrough in the teaching of statistical techniques by making the
learning process interactive and fun.
The participants are introduced to a process out of control. Using a series
of measurement techniques to analyse the current performance, to diagnose
the causes of failure, to eliminate variability and to bring the outputs
under control, they find they can make the process capable.
SERVICE TO
PLEASE
Exposing your people to the realities of meeting internal and external
customer needs is a very effective technique for improving business
performance. We show how to identify those needs and how to develop
strategies to ensure that customers become increasingly pleased with the
service they receive.
The module covers: refocusing the company, identifying customers and their
needs, internal and external customers, customer/supplier relationships and
the principle ideas behind "50,000 Moments of Truth". The theme
is: "If you don't have a customer, you don't have a job. So let's figure
out who your customers are and what must be done to excite them."
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SMART
CHANGEOVERS®
Changeover reduction can provide immediate cost and productivity benefits,
often for only a small investment. Optim's Smart Changeovers® program is by
far the most popular one of its kind in Australia, having been attended by
over 1000 people and 300 companies in the last two years in Australia, New
Zealand and North America. The emphasis is on teamwork and creativity in
devising low cost solutions. The program can be run over two days on your
site and is designed for operators, maintenance fitters and their leaders.
This course is an optional module for the Leadership ll Certificate -
a Frontline Management Course.
SMART
CHANGEOVERS® BLITZ
Optim's Smart Changeovers® Blitz process provides a practical team based
approach for the systematic reduction of time loss during changeovers,
set-ups, start-ups, shut-downs and routine maintenance functions.
The concepts are applicable to all areas of a business and are the same as
used in the normal two-day Smart Changeovers® course. However, this program
provides a sharp kick-start to reinvigorate a previous changeover reduction
campaign. Extra tools for analysis are taught and, in a highly intense hands-on
program, the focus is on one machine. The changes are made and demonstrated
during the workshop. Reductions in excess of 50% are targeted and usually
achieved before the end of the workshop.
The program encourages the collective effort of operators, support staff,
engineers and management to work together to devise low cost, imaginative
solutions to traditional problems and implement them immediately. The whole
process takes two days and must be run on site.
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STATISTICAL
PROCESS CONTROL
This two-day workshop gives attendees a deeper understanding of the
fundamentals of statistical process control and how to use statistical
tools to improve control over their processes. The attendees learn the
fundamentals of SPC through a series of creative and interactive exercises
and activities.
The course starts at the basics of probability and variability then
progresses through histograms, control charts and process capability. The
use of SPC software and FMEA analysis is also included in the second day.
At the completion of the course attendees are expected to carry out an SPC
project.
This course is generally tailored to suit the level of knowledge of the
attendees.
This course is an optional module for the Leadership ll Certificate -
a Frontline Management Course.
STATISTICS
SUCKS
The participants are introduced to a cannon that can't hit the target. A
serious problem experienced by every company, every day!?
We use a touch of Juran, a pinch of Pareto, a dab of Ishikawa and a
generous sprinkling of Deming. Hey presto! The problem is solved - and not
a headache in sight. Who were these guys anyway that they should confuse us
with statistics when all we needed was a bit of team based common sense?
This short course covers the concepts:
· Process Measurement
· Process Capability
· Variability Reduction
· Process Improvement
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TEAM
BUILDING
Having a workforce that is motivated, flexible and willing to work together
is every manager's dream. This really can be achieved over time if the
right environment and foundation exists, and if the employees understand
how to draw on their total pool of talent.
Team members need a whole suite of new improvement skills today to
contribute fully to the future of the company. If delivered all at once,
they tend to be quickly forgotten. Optim's approach to team building
provides the people short injections of interactive training over an extended
period of time, which progressively builds a portfolio of new and useful
abilities.
Through Optim's progressive approach, people gradually learn and try things
out, so gaining confidence and proficiency. This leads to a sustained and
stable team environment.
THE ILLS OF
INVENTORY
Inventory is the manifestation of all the ills we live with in industry.
Why is it there? What does it cost? What can we do about it?
This program is designed to help operational people to understand the
effect that inventory has on lead-time, operating costs and service levels.
It puts inventory reduction in context with other concepts for continuous
improvement and explains the contribution that everyone can make to avoid
accumulation of materials and all other resources.
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VALUE ADDED
MACHINES
Value Adding Machines embodies the best principles of Total Productive
Maintenance into a simple step-by-step process to helping operators and
their maintenance colleagues to work together to achieve optimum
performance from the value adding equipment.
Value Adding Machines targets:
· zero downtime
· zero material waste
· machines that get better over time
The Value Adding Machines process transfers daily maintenance
responsibilities to operators and provides maintenance crews with a
framework for the longer term management of equipment effectiveness.
VALUE ADDED
PRODUCTIVITY ANALYSIS
Peter Drucker said that total enterprise productivity is the only true
measure by which to judge and reward the efforts of management and
employees. Value Added Productivity Analysis [VAPAâ] is becoming the means
by which companies are determining how effectively capital, equipment and
labour resources are being used. The output of this very comprehensive analysis
is providing the means for:
· enterprise performance measurements
· enterprise agreements
· enterprise benchmarking
· uniting all employees through a common cause - to create wealth for all
stakeholders
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VALUE STREAM
ANALYSIS
Optim’s Value Stream Analysis is a process for analysing all the actions
and tasks that go to delivering your product or service to your customers.
It applies to both internal and external customers and clients.
It aims at improving the whole process not just optimising parts of it, and
when used with powerful tools such as Optim’s New Generation Problem
Solving and other team based methodologies, can give a strategic advantage
previously only dreamed about.
Utilising the best knowledge base available to your company, your employees
who are doing the job everyday, the existing processes are analysed, the
knowledge shared and a new vision created.
The teams empowered by this knowledge assess all aspects of the value
stream and make recommendations to Management on their course of action. A
mandate is constructed allowing for boundaries to be set to cover Safety,
Quality, Capital Expenditure, Research and Development, various
accreditations and Maintenance Procedures so that none of these are
compromised in the process.
Optim’s Value Stream analysis can help your Continuous Improvement process
by sharing more information with a greater number of staff.
It can revitalise previous efforts and really contribute to the “bottom
line results” you expected from your Continuous Improvement Program but are
not realising.
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WORK-CENTRE
IMPROVEMENT
This unique program by Optim helps operators and maintenance personnel on
process lines to decide for themselves how to get the best out of their
equipment. Work Centre Improvement uses operator experience and our tools
for analysis to identify the end products critical-to-quality requirements.
They then determine the inputs and skills required to achieve those
outputs. The team then drafts its own work instructions, decision rules and
monitoring procedures to ensure the critical-to-quality outputs are
maintained.
The program turns into a project to address skills and knowledge
deficiencies and to standardise work practices. In this way, Work Centre
Improvement totally compliments ISO 9000.
WORKPLACE
REDESIGN
The drive to reduce batch sizes, to improve response time, quality and
flexibility, has encouraged many companies to rethink the way in which they
organise their total manufacturing resource. For high, medium and some low
repetition industries, Group Technology and Cellular Manufacturing provide
the means for achieving these and many other benefits without the need for
additional equipment. This program covers all the essential design issues
for plant engineers and management, including level scheduling, visual
management, JIT, kanban, etc.
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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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