Systematic - Hands on - Effective
Root Cause Analysis
This workshop is an improvement activity to be carried out by a multifunctional team, which is designed for learning and practical application of basic improvement tools and focus improvement methodology, leading to the permanent elimination of any kind of losses within the productive, administrative, warehousing and material handling processes. Its structure allows the client team to obtain quick improvements, based on the identification of the root causes of the losses and the implementation of solutions to eliminate them. The workshop is facilitated using unique technology developed by OpExApps which can be use by the team to extrapolate learnings and savings against other losses.
1. Acquire the adequate knowledge to support the continuous improvement process within the organization.
2. Understand the meaning of the KAIZEN process, including the concepts of absolute zero and cost-benefit ratio, to support the improvement of the business profit.
3. Develop practical skills in the use of basic continuous improvement tools, such as 5Gs, 5W1H, 4M and Why / Why analysis.
4. Promote teamwork, where adding value to the business becomes the most important objective.
5. Motivate the permanent identification of opportunities for business value improvement, during the daily work activities.
SMED: Changeover Optimization
This workshop is an improvement activity to be carried out by a multifunctional team. It has been designed to improve the availability and efficiency of production lines, safety in operation, product quality and reduction of waste, through the optimization of the time and process required to make changeovers. Participants will gain practical knowledge of simple, but effective improvement techniques that can be easily used in other areas of the plant to support the overall improvement process. The workshop is facilitated using unique technology developed by OpExApps which can be use by the team to extrapolate learnings and savings against other losses.
1. Understand the meaning and proper application of the SMED methodology, which will enable easy replication of the process in other areas of the client's manufacturing area, maximizing the profit for the business.
2. Develop practical skills in the use of improvement tools, such as product changeover matrix, spaghetti diagram, internal and external operations, ECRS, Gantt chart, standard working instructions and one-point lessons.
3. Improve the motivation to achieve goals related to: changeover standard time, waste reduction and elimination of errors and machine adjustments post-changeover.
4. Encourage the use of 5Ss, the implementation of infallible solutions and initiate the introduction of the concept of "visual plant".
5. Review and improve safety practices related to de-energization and effective equipment lock out – tag out.
Steps 0 - 3
This theoretical / practical workshop explains the basic concepts and benefits of the Autonomous Maintenance philosophy. Participants will gain theoretical and practical knowledge on how to prepare and plan the introduction of the methodology in manufacturing equipment as well as how to perform steps 0 - 3. The workshop emphasizes the importance of carrying out the activities in a safe way, based on simple but effective maps and risk analysis. The activity introduces continuous improvement tools that are easy to implement, leading to improvements in equipment efficiency in the short and medium term. The workshop is facilitated using unique technology developed by OpExApps which can be use by the team to extrapolate learnings and savings against other losses.
1. Understand the principles and objectives of the philosophy of Autonomous Maintenance.
2. Introduce the program basic theoretical concepts of steps 0 -3, which combined with practical activities will allow to clearly understand the objectives and goals of each.
3. Develop practical skills in the use of continuous improvement tools, such as tagging for safety, operability and maintenance, safety risk map, effective machine setting, 5Ss and principles of operation.
4. Promote teamwork between the areas of operations and maintenance, leading to the improvement of the operational efficiency of the manufacturing equipment.
5. Initiate the process of elimination of minor and major stops due to equipment natural deterioration. Initiate the process to enable a more autonomous operation. Both are replicable throughout all customer manufacturing areas.
PROJECT EARLY MANAGEMENT & DESIGN FOR QUALITY - how to prevent losses and ensure vertical starts
This theoretical / practical workshop explains the basic concepts and benefits of the early management methodology applied to various projects, such as slight changes in plant configuration, equipment improvement, manufacturing lines expansion, new products, new processes, new plants, processes or manufacturing technologies.
The methodology is based on the front-loading concept, where an early identification of potential risks and losses allows the development of design review checklists (including specific validations checklists), enabling the development of effective action plans. This will be achieved through workshops and a rigorous gate control process carry out by multifunctional teams. The risks and losses could be related to any function but the focus of this workshop is design for Quality.
In addition, the methodology optimizes new products margins and the capital investment by optimizing the design and life cycle cost of the Project.
The relationship of identifying and eliminating losses during the design phase, rather than during the start-up phase of a project, can be from $ 1 to $ 10,000, so proper application of the methodology depending on the size of the project can generate economic benefits of hundreds of thousands of dollars, in addition to enabling compliance with Quality corporate and legal standards.
1. Understand the principles and objectives of the philosophy of early product and early equipment within the context of the development of new products. At the end of the workshop a preliminary risk analysis is generated which will serve as a basis for the application of the methodology during the actual execution of the project.
2. Develop practical skills for the proper use of early management tools such as, design for easy manufacturing, maintenance prevention information, life cycle cost, functional design elements, quality design review checklists, factory acceptance and installation, operation, production and manufacturing validations.
3. To promote teamwork among the different functional areas involved in the development and execution of the projects, to aim at vertical start-ups, minimizing quality losses and maximizing the return on investment while enhancing the products margin.
4. Initiate the process of identification and use of maintenance prevention information and the development of own design review checklists, to build an effective continuous improvement process for projects execution.
5. Introduce the concept of building quality from the design phases of the project, supported by specific responsibilities matrices.
This workshop is a practical improvement activity, to be carried out by a multifunctional team, which has been designed to evaluate 10 critical elements within the process of identification, quantification and reduction of waste, generated in processes and / or manufacturing lines. The methodology used in the workshop is based on an evaluation of the current waste management process, which allows to easily identify the gaps against the benchmarking on which the model development was based. The short-term benefit to the customer will be a reduction in manufacturing cost, which can translate into thousands of dollars, allowing immediate replication at any other area that generates significant waste at the customer's premises.
1. Evaluate and optimize the waste management process focused on the area with greater losses in terms of money, not volume.
2. Develop practical skills in the use of improvement tools, such as loss tree, loss mapping, basic statistical control, compatibility and reprocessing matrices, absolute zero concept, and optimization of the production plan.
3. Elaboration of the radar chart of the improvement process, which allows an immediate visualization of the current state of the program and an easy definition and visualization of the objectives in the short term.
4. Develop a SWOT analysis, as a support tool for the strategic planning of the waste reduction plan.
5. Development of a specific improvement plan, derived from the practical use of the model.
3. Follow-up of the execution of the action plan and the achievement of the objectives defined during the workshop.