We propose, in a matter of days, LEAN solutions adapted to the case in question, based on “Best Practices LEAN” product of our cases solved over many years in three key Business Processes:
1. Manufacturing, from the first production operation to the last
2. Supply Chain, from the arrival of an order until all the line items are delivered and charged
3. Industrialization of New Products, since Marketing idea a new Product / Service until it occurs to the cycle required by Sales
The large number of times in the past we had to design from scratch, makes us not surrender to the problem No. 45 and we have maximum confidence that, working deeply on the root causes, the ideal solution for any situation will always appear
Very few people dominate micro-operation as our consultants. This is a consequence of the clear strategy marked from the beginning by the partners of Dit Consulting to be present at GEMBA (the workplace where things happen), and to be there the necessary and sufficient time to see / know / document / classify the production / assembly operations at the level that is needed to detect wastage and discover the root causes to eliminate them in the design phase
It allows manufacturing industries to analyze and experiment with their processes in a virtual environment, enabling decisions that can improve efficiency at the lowest possible cost.
The 3D simulations in FlexSim® emulate the appearance of the real system including production, transports between processes, stock in progress, assembly, inventory level and shipments, thus being easier to see and understand what is happening. and its root cause. The equipment is created to scale on the layout in CAD and presented using 3D models, making it easier to see and recognize bottlenecks, waste in the production line or other deficiencies within the system.
The Lean Model is based on the Toyota system and proposes the following steps to reach excellence:
Design of solutions for the maximum simplification of productive flows and elimination of operations without added value.
Sized layouts and preliminary engineering designs, enough to carry out the implementation of the solutions.
Indirect re-engineering for process management.
Horizontality in vertical flow charts and productivity improvement.
Blueprints for New Plants & Factories
Considering Lean concepts when designing a plant is essential, both in the production process (core), as well as in other requirements or subsystems that influence the design (process requirements, construction, labor and environmental legislation, etc.)
From our experience, having a good preliminary draft for a New Plant means avoiding many problems in the development of the implantation and later in the operational functioning.
The experience of DIT Consultoría in this section is based on the knowledge obtained in the projects in which we have participated for new plants, transfers and layout modifications in existing plants.
Total Productive Maintenance
The main concepts for the implementation of an improvement program of equipment maintenance and facilities are the promotion of
PARTICIPATION + EFFICIENCY + MANAGEMENT:
Defining and managing the associated corrective, preventive, predictive, autonomous maintenance processes...
The objective is to improve the availability of the machines by increasing reliability and safety.
To do this, an important help is to have an extensive maintenance database and appropriate KPIs to follow company results.
Lean Thinking + 4.0 Industry Fusion
Industry 4.0 (Digitization of the industry and set of associated technologies), allows the capture, communication and analysis of different information layers inaccessible years ago.
The main axioms of Industry 4.0 are: real-time interconnection, effective and rational automation, instant massive data analysis, and advanced technology and digitization.
In addition, the associated information systems must provide correct support to the process operation and serve as facilitators of the same.
We have experience on ERP solutions and more specific solutions depending on the area and functionality to be covered.
From DIT, we apply this fusion as integrators, defining the system requirements as connoisseurs of the associated technologies.
Supply Chain and Strategic Procurement
Redesign and implementation of the complete supply chain to improve material lead times and procurement costs.
We help our clients to redefine their supply chain based on total customer orientation, eliminating departmental inefficiencies and barriers, achieving maximum flexibility and redefining operations by focusing on individual processes.
We diagnose and redesign the supply chain from when an order is received until it is delivered, taking into account the value that the customer perceives and for which he pays.
Associated projects: commercial management, strategic purchasing, internal logistics, procurement, external logistics and transportation.
Time to Market
All sectors of the economy have an increasingly rapid product evolution.
The speed of creation of new products becomes a fundamental competitive advantage to achieve greater market shares.
Our approach to these time to market projects pursues two very clear objectives: reduction of industrialization lead times and costs.
We base the concept on an integrated vision of processes, systems, organization and people.
Design to Cost
The cost of the product arises in the design phase, being as important that aesthetics and functionality have a good acceptance by the market, as that the manufacturing costs and the materials used are adequate to achieve the objective profitability of the product.
What we offer through this service is to reduce product costs through value analysis.
It is essential to understand the functions for which the product in question has been designed and analyze those for which the client is willing to pay, to then proceed with the development of redesign set of actions with implemented savings and without putting quality at risk.