Innovating the Factory
A step by step approach
Charting a New Course: Quoting (or Costing) products with vision of the future
- Quote new work based on how to perform with Lean operation
- Find price point at different levels of efficiency (elimination of waste)
- Know how you have to operate to maintain profit margins
- Justify investments in new machines and processes
Solution: Actual Cost Modeling - costing software to calculate cost with various methods of operation and different levels of efficiency (elimination of waste)
Preparation: Preparing the organization for transition to Lean Manufacturing
- Identify project leaders and train these leaders
- Provide project leaders with tools and techniques of Lean Manufacturing
- Place these leaders in the role of teacher
- Establish a hand-off from planning to execution
Solution: Lean Manufacturing Roadmap - educational materials for learning and training others in the principles of lean manufacturing
On the Journey: Changing from batch to flow operation
- Replace work orders with visual signals
- Substitute flexible labor for work in process inventory
- Model the plan prior to Kaisen events
- Establish a single operation plan for the shop floor
Solution: Lean MAST - simulation and modeling software for the study of optimal manufacturing operation.
Maintaining Course Direction: Self-maintaining daily measurements for continuous improvement
- Identify cost drivers in your operation
- Record daily performance metrics
- Measure Kaisen event outcomes
- Benchmark actual operation against planned operation
Solution: SAIL - software that manages your daily playbook of operations plan through scheduling (calling plays) and monitoring actual cost
All of these ideas and software products can become part of your organization through the assistance of CMS Research. We have been to the lean manufacturing world and can show you the way.
