Process Improvement
Turn-Key Industrial Engineering Services uses the Kaizen philosophy of continuous improvement. Each individual process improvement is incremental and has a relatively modest impact by itself. However, the sum effect of all the improvements creates a substantial amount of cost savings. This philosphy has been very successful, saving our clients an average of $161,000 annually. These savings are achieved by more efficient use of utilities, inventory, equipment and labor. Turn-Key uses a three phase process to identify, define and implement process improvements throughout the entire production environment. In addition, Turn-Key provides Statistical Process Control Analysis to ensure that the improvements made in your operation are permanent.
Process Improvement Integration
Phase I
Turn-Key will provide a Phase I study to identify current facility production capabilities and pinpoint potential bottlenecks.
The study begins with a 2-day on-site review of the facility’s production and utility systems. During the review, Turn-Key will collect detailed information about the facility production equipment, work standards, and utility systems. Typical information collected includes quantity and type of production and utility equipment, product mix, production hours, staffing levels, work-in-process (WIP) storage, inventory levels, and current production standards by department. This data will be used to develop a capacity model that calculates the facility’s production and utility capabilities.
Finally, the results of the capacity model are assembled into a written report which includes the following information:
- Production and utility data used to develop the model
- Production equipment and employee capacities
- Production capacity summary
- Production ratings
- Utility capacities
- Utility capacity summary
- Utility ratings
- Production balancing charts
The report will include a written summary of the production and utility data listed above as well as a section highlighting potential production and/or utility bottlenecks. A final site visit is included to review the results of the study with the client.
Phase II
Turn-Key will provide a Phase II study to define process improvements that will increase productivity and reduce process bottlenecks. The results of the Phase I study will be used to pinpoint opportunities for increasing production capacity and efficiency.
The study begins with a 3-day on-site review of the facility production processes. During the on-site review, Turn-Key will work on the plant floor with the production employees collecting information needed to identify potential process improvements. Typical data collected includes material workflow, information workflow, process scheduling, department responsibilities, standard operating procedures, and employee process improvement suggestions. This data will be used to define process improvement opportunities.
Finally, the results of the Phase II study are assembled into a written report that includes documented process improvements, implementation procedures, and anticipated cost savings. A final site visit is included to review the results of the study with the client.
Phase III
Turn-Key will provide Phase III services to implement the process improvements identified during Phase II and document the effect of those improvements. Turn-Key will be on-site working with plant personnel to execute the process improvement implementation plan and measure the results. The results of Phase III are assembled into a written report and reviewed with the customer. The final scope and duration of Phase III will be identified once Phase II has been completed and the quantity of process improvement work is defined.