Analysis
A typical analysis includes a small team of Equinox Consultants and few people from the client's staff. Together we observe the operation, interview, collect data, and Value Stream Map the entire process from end to end.
Results typically include: quantitative and qualitative reports, the completed Current State Value Stream Maps, Future State Map, Spaghetti Diagram, list of prioritized opportunities, a list of easy-to-achieve improvements, presentation to management, and recommended future path with project time and schedule.
Additional benefit: The client team works directly with the Equinox team. They learn the value stream mapping process, some analysis techniques and begin the formation of a team of improvement leaders for the site.
The analysis consists of:
Observing the current state of activity
Interviewing workers
Building an understanding of the processes
Examining the measurement process
Documenting the results
Providing the client with a quantitative as well as a qualitative report, with a prioritized list of opportunities
The aim is the identification of opportunities for improvement in the process leading to:
Greater customer satisfaction based on lower pricing, faster delivery, or better response to changing orders
Optimization of internal resources like capacity, inventory, workforce, floor space
Improved safety, morale, and workforce effectiveness leading to greater productivity
Better internal communication
Reduced design and quality issues
More effective supplier interaction
Implementation
Implementation is the stage after the identification of an opportunity for improvement and consists of:
Establishing the Improvement Goal and Scope
Assigning Equinox staff and Client staff to the effort
Developing the time frame and milestones
Determining if Kaizen approach (short term, focused approach) or On-going approach is appropriate
Measuring the process to get Baseline Metrics
Making the improvement (s)
Documenting the results
Providing the client with a quantitative as well as a qualitative report of results
Indicating steps for further improvement
Training
Our approach is Train and Do. There is a period of training with a slide presentation and some class participation exercises, followed by the application of the material in an actual improvement effort.
Class TopicsLength of Class & Implementation
5S - Workplace Organization 2-5 Days
Value Stream Mapping 2 Days
Flow Manufacturing 5 Days
Visual Factory Management 2 Days
Lean Approach to Design Engineering 2 Days
Setup Reduction 2 Days
Work Cell Creation 5 Days
Total Productive Maintenance 2 Days
Cross-Functional Team Training 2 Days
Training Description
5S - Workplace Organization - Training in the goal, importance, achievement of, and maintenance of an organized workplace. Equally applicable to production or office processes. After the training, a team of 5-7 people will select, develop a plan, and '5S' an area. 2 Days
Value Stream Mapping - Training in how to identify and remove waste from processes. A Macro and Micro Value Stream Map will be created during training. Equally applicable to production or office processes. After the training, a team of 5-7 people will select and map an area, develop a plan for and start some waste removal efforts for that area. 2 Days
Flow Manufacturing - Training in Flow techniques and concepts such as one-piece production, pull system, kanban, make to customer demand, co-location of resources, and line balancing and sequencing. After the training, a team of 5-7 people will select and flow map an area, develop a plan for and start arrangement of equipment to create production flow. 5 Days
Visual Factory Management - Training in Visual Factory techniques with the goal of creating a work place that communicates. After the training, a team of 5-7 people will select an area, develop a plan for and create a system of highly visible, easy to understand and maintain measurements.
Project Management
Project Management is offered to Clients to provide overall coordination, guidance, leadership, and focus for numerous improvement efforts and teams.
A Project Manager: Keeps each team focused on its goal and milestones
Answers technical questions
Guides teams through difficult
Acts as liaison between the Upper Management and the teams
Monitors progress
Prevents overlap of efforts
Reports periodically to Upper Management
Project Management can be determined and scheduled based on the needs of the project.