| How We Work
By working in many factories over the
years, we have observed recurring patterns both in technology
and in human behavior. This experience has coalesced into
a set of guiding principles that we use to help our clients
set strategies.
- Address
changes with all 3 aspects of a lean enterprise: Core
Process, System, and Organization
Streamline Strategy Japan has created a unique combination of technology
and services that is specifically designed to support
the real-world requirements involved with a lean conversion..
- Visibility of operating
conditions and production plans are the hallmark of
a productive plant.
Equipment status is visible even from afar, defects
stand out, and production instructions are clearly displayed.
No excess WIP blocks the view, and materials handling
has been streamlined. Work areas are clean, orderly,
and well marked.
- In the
age of operator-machine systems, operators are the determining
factor of productivity.
Analysis of operator work content is essential. No machine
will run properly unless instructions are given to operators,
with training and regular updates.
- Operator
involvement in improvement projects is essential to
success.
Only machine operators know the details of their problems.
The projects we recommend typically do not require heavy
investments but rather small groups implementing simple
changes with small budgets, based on their own ideas
but with large cumulative effects.
- We help
our clients focus on internal causes of inventory
accumulation.
Inventory accumulates due to several causes acting in
conjunction. FIrst, work in process buffers are used
to alleviate capacity shortfalls. Production planning
assumptions of long lead times are self-fulfilling.
Long changeover times force long production runs. Inefficient
distribution and logistic systems need inventories at
various locations. Unlike market forecasts, production
capacities and process flexibility are internal factors
that can be acted upon.
First, we analyze the existing production
system. We review documents, interview plant personnel,
and observe the shop floor. We examine the following elements:
- Product structure. Families and production
quantities
- Demand. Seasonal variations, growth
trend, and other fluctuations
- Process capabilities and capacities.
- Production planning and control.
Methods and effectiveness
- Inventory status and policies. From
raw materials to finished goods.
- Quality. Policies, methods and systems.
- Equipment. Maintenance practices
- Organization. Structure, role of
super-visors, and operator work content
We recommend two or three pilot projects
for immediate implementation, and supply detail-ed plans.
These projects may affect the process structure, equipment
selection, materials handling methods, production planning,
and shop layout. We provide a cost/benefit analysis and
estimates of implementation time and human resource requirements.
We monitor progress through periodical
plant visits, during which we provide guidance to project
teams. Once the plant has successfully completed the pilot
projects, we help expand the activities to an entire production
area When success has been achieved on this scale, our
client is able to replicate it in other production areas
with its own staff, trained by Streamline Strategy Japan experts. |
