Ask for our complete package of features and service solutions in Lean.

We provide pre-studies and you get a second opinion how to improve the efficiency and quality.

It takes from 3 days up to 4 weeks.

Prologia offers LEAN approach for your processes. Now you can optimize your work stream by using our Lean expertise and methods in

• Waste time elimination
  
  • Reduce Over-production or service
  • Eliminate Waiting-time
  • Eliminate material flow that doesn’t support immediate production
  • Keep only value adding processing
  • Inventory reduction with JIT philosophy
  • Motions study and balancing to eliminate waste
  • Defects reduction and eliminate rework and repair
   
• Value Stream mapping
  • Is a Lean technique used to analyze the flow of materials and information currently required to bring a product or service to a consumer. At Toyota where the technique originated, it is known as "Material and Information Flow Mapping".
  • Value stream mapping is a helpful method that can be used in Lean environments to identify opportunities for improvement in lead time. Although value stream mapping is often associated with manufacturing, it is also used in logistics, supply chain, service related industries, healthcare[3], software development, and product development.

  We can identify seven value stream mapping tools and they are:

   

  1 Process Activity Mapping

  2 Supply chain responsiveness matrix

  3 Product Variety Funnel

  4 Quality filter mapping

  5 Forrester effect mapping

  6 Decision point analysis

  7 Overall Structure Maps
   

• KanBan systems in sourcing from suppliers
  • Kanban maintains inventory levels - a signal is sent to produce and deliver a new shipment as material is consumed. These signals are tracked through the replenishment cycle and bring extraordinary visibility to suppliers and buyers
• KanBan systems internally
  • Kanban is a signaling system to trigger action. As its name suggests, kanban historically uses cards to signal the need for an item. However, other devices such as plastic markers (kanban squares) or balls (often golf balls) or an empty part-transport trolley or floor location can also be used to trigger the movement, production, or supply of a unit in a factory.
• 5 S implementation
  • 5S is a reference to a list of five Japanese words which 'start' with S. This list is a mnemonic for a methodology that is often incorrectly characterized as "standardized cleanup", however it is much more than cleanup. 5S is a philosophy and a way of organizing and managing the workspace and work flow with the intent to improve efficiency by eliminating waste improving flow and reducing process unreasonableness.

• Continuous Improvement solutions using Kaizen
  • In the context of this article, Kaizen refers to a workplace 'quality' strategy and is often associated with the Toyota Production System and related to various quality-control systems.

    Kaizen aims to eliminate waste (as defined by Joshua Isaac Walters "activities that add cost but do not add value"). It is often the case that this means "to take it apart and put back together in a better way." This is then followed by standardization of this 'better way' with others, through standardized work.

• TPM (Total Productive Management)
  • TPM is a new way of looking at maintenance, or conversely, a reversion to old ways but on a mass scale. In TPM the machine operator performs much, and sometimes all, of the routine maintenance tasks themselves. This auto maintenance ensures appropriate and effective efforts are expended since the machine is wholly the domain of one person or team. TPM is a critical adjunct to lean manufacturing. If machine uptime is not predictable and if process capability is not sustained, the process must keep extra stocks to buffer against this uncertainty and flow through the process will be interrupted.. One way to think of TPM is "deterioration prevention" and "maintenance reduction", not fixing machines.
     
• Visual management
  • Makes problems visible and helps staff staying in direct contact with the reality
     
• Set-up times reduction using SMED (Single Minute Exchange of Dice) originally from Toyota
  • Is one of the many lean production methods for reducing waste in a manufacturing process. It provides a rapid and efficient way of converting a manufacturing process from running the current product to running the next product. This rapid changeover is key to reducing production lot sizes and thereby improving flow
     
• JIT solutions
  • Is an inventory strategy implemented to improve the return on investment of a business by reducing in-process inventory and its associated costs.
     

• Cellular Manufacturing
  •  is a model for workplace design, and is an integral part of lean manufacturing systems. The goal of lean manufacturing is the aggressive minimization of waste, called muda, to achieve maximum efficiency of resources. Cellular manufacturing, sometimes called cellular or cell production, arranges factory floor labor into semi-autonomous and multi-skilled teams, or work cells, who manufacture complete products or complex components. Properly trained and implemented cells are more flexible and responsive than the traditional mass-production line, and can manage processes, defects, scheduling, equipment maintenance, and other manufacturing issues more efficiently
     
• Takt time introduction
  • Can be defined as the maximum time allowed to produce a product in order to meet demand. It is derived from the German word taktzeit which translates to clock cycle. There is a logic therefore to setting the pace of production flow to this takt time. Product flow is expected to fall within a pace that is less than or equal to the takt time. In a lean manufacturing environment, the pace time is set equal to the takt time.