ProVantage - Lean Manufacturing program
QMI Solutions developed the ProVantage Lean Manufacturing program as an intensive four-day program focusing specifically on world's best lean manufacturing processes but also assisting companies gain maximum benefits through their implementation.
WHY LEAN MANUFACTURING?
Lean Manufacturing is a business philosophy characterised by the endless pursuit of waste elimination.
Lean organisations understand that waste can take many forms as any resource or activity, which is not continuously adding value to the customer, is a form of waste. The most successful organisations are those who are able to identify all the hidden forms of waste that we normally take for granted, such as inventory, excess space and the movement of materials or people.
By implementing lean practices your organisation will:
- increase throughput
- reduce operating expenses and inventories
- improved cultural change
- improved quality and reduced scrap/rework
- reduced lead times and greater supply chain responsiveness
- improved participation, communication and collaboration across the supply chain
- improved fulfillment of your order winning criteria of your customers - cost, quality, lead time, flexibility and information.
HOW LEAN ARE YOUR PROCESSES?
ProVantage conducts an in depth analysis of your company's practices to see how you rate. Many companies are surprised at how poorly they rate when it comes to lean manufacturing practices, but this is not a negative revelation.
Quite the opposite, a rating of the practices clearly highlights the areas in which your company is deficient, and ProVantage shows you the steps to remedy these dysfunctional practices and prescribe an action plan to get you on track to reduce waste and improve productivity.
SO HOW DO I BECOME LEANER?
You become leaner by implementing lean best practices - ProVantage will show you how by taking you through the following steps:
Lead and manage change with concepts and tools from the world's leading change experts, including Kotter's eight points for successful change, stages of change and dealing with resistance.
Build and centre your teamwork activities around the empowerment and involvement of frontline workers on a common set of targets to drive continuous improvement and sustainable performance.
Understand the practice of continuous improvement in the workplace by focusing on eliminating major losses and waste through structured problem solving.
Implement 5S to clean up and organise your organisation. The world's best manufacturers suggest that if you cannot excel at 5S you cannot expect to excel at anything in manufacturing.
Learn the importance of visual performance measures in driving changes in behaviour and the benefits of displaying visual measures to your workforce. The whole organisation is able to see exactly what is being measured.
Focuses on prevention of breakdowns and deterioration of equipment through a preventative maintenance program. Learn how to eliminate problems before they occur through operator-based maintenance and condition monitoring.
Identify and eliminate the seven wastes in production and the six major machine losses. Waste is anything that uses resources but does not add real value as determined by the customer. Be able to practically apply techniques to reduce or eliminate the losses and wastes.
World class manufacturing deploys pull systems to control the flow of product from one process to another. Upstream processes will only transfer products when the downstream process requires it. Learn the "Theory of Constraints" on how to detect and protect your throughput potential.
Clarify complex systems through Value Stream Mapping, allowing identification of problem areas and a tool for effective planning of solutions and their implementation. Value stream maps are live documents which should be refined and updated as the system changes or additional information is collected.
Learn how to develop relationships and strategic alliances, and collaborate with supply chain business partners with a common focus on end customer needs.
Understand the need to reduce set-up times in terms of your organisation's quest for flexibility, competitiveness and contribution to your overall equipment effectiveness.
ARE YOU READY TO BECOME WORLD CLASS?
There is a standard scoring method we use to illustrate how "mature" you are when it comes to world class practices such as lean. Many companies are surprised at how low they rate on this scale, but it gives them the impetus to see what areas need to be addressed. The stages of practices maturity look like this:
Stage 1 - No best practices used and the company revolves around crisis management and ad hoc responses.
Stage 2 - Clearer understanding of company direction, imparted effectively by management.
Stage 3 - There is an ownership of practices at shop floor, middle management and senior management levels.
Stage 4 - Practices are constantly being honed and refined. Management is consultative and the company is utilising technologies to improve performance throughout the entire supply chain.
Stage 5 - Best practices are a 'way of life'. Management has adopted a mentoring style with the company and its supply chain business partners
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