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Our method :

The Lean and Flow Manufacturing Implementation Services will help companies to implement the Lean and Flow principles quickly and safely and to achieve the aimed targeted benefits.

Employees work directly with REOSS team members via a structured proven implementation method. This structured implementation method consists of 6 phases, which are well defined and very effective in the execution.

Phase 1 - Lean and Flow Manufacturing
Implementation Master Plan / KICK-OFF

• Define Target area & Scope of project (products, volumes, etc.).
• Define Implementation Team members (Process & Product Team).
• Define Steering Committee.
• Define Targeted Benefits.
• Define Lean & Flow Line Measurement tools.
• Define Project Milestones.
• Initial data gathering (Process & Product).
• Define communication program.
• Define employees training program.

PHASE 2 - Initial Lean and Flow Line Design
and Initial Kanban Sizing

Product Team Activities
• Vpast Analysis.
• Define Vmax.
• Create the Bill of Materials (BOM).
• Define material replenishment strategy.
• Add the supplier information to each item.
• Create Kanban Master file.
• Calculate Initial Kanban sizes.

Process Team Activities
• Identify the product families and products.
• Create Process Synchronisations and Multiple Model Process Sync.
• Create Process Map on Process Sync basis.
• Split the Sequence of Events (SOE) by product family or by product.
• Classify the VA from the NVA and the Quality steps in the SOE.
• Transfer cycle time from SOE to Process MAP.
• Identify the various hindrances following the 5M (Men, Method, Material, Machine and Management).
• Define for each Process the ratio of scrap, rework and calculate again the Vmax.
• Add time in Multiple Models Process Sync and calculate the Critical Path.
• Define the setup time for each machine.
• Define the Effective Hours of each Process. (At first the number of Shifts = 1).
• Calculate the Takt Time of each Process.
• Calculate CTw (weighed CT) of each Process.
• Get the CT max of each Process.
• Calculate the number of Resource Operation (#ResOPs) of each Process with the CT max.
• First analysis and comparison with the inventory.
• First Operation Design.
• Put the IPK.
• Identify the Processes with a Buffer IPK.

PHASE 3 - Lean and Flow Line Design
and Final Kanban Sizing

Product Team Activities
• Final Kanban calculation in the Kanban Master according to Vmax.
• Define the consumption and the re-supply locations of each article.
• Define space and volume in the workstation and in the RL using Kanban calculation.
• Assign each article to workstations further to SOE and Process MAP.
• Define the updated Kanban Master.

Process Team Activities
• Finalize Multiple Model plan, calculate Takt, #ResOPs, etc.
• Final Operation Design.
• First Layout according to the Operation Design.
• Complete and formalize the Processes.
----- Process Synchronisations
----- Critical Path Calculation
----- Multiple Models and Process MAP
----- Sequence of Events

PHASE 4 - FINAL LINE DESIGN / Line Live

Product Team Activities
• Calculate Kanban space and volume requirement at each Pull Sequence.
• Define supply standards.
• Describe supply organization.
• Define supply path and related means.
• Define each member roles and responsibility.
• Set-up supply chain plan.
• Backflush design.
• Audit of the Kanban procedure (Calculation and organization).

Process Team Activities
• Final set-up of line design.
• Audit of correct usage of SOE. Content of sequences and VA ­ NVA analysis.
• Final line balancing. (at +/- 10%).
• Daily Rate Planning & Resource Simulation.
• Set-up Lean & Flow Measurements.
• Flexible operator qualification plan.
• Audit of updating data procedure.
• Define Capital Expenditure and Resource Plan.

PHASE 5 - Lean and Flow Line Certification

Product Team Activities
• Standardization of Kanban data tools.
• Formalization of sequence of events.
• Material definition.
----- Cases and shelves
----- Kanban labels
• Operator training further to the established procedure.

Process Team Activities
• Definition of Mix Model rules.
• Definition of VGI (Visual Graphic Instructions).
• Final audit of the updating data procedure.
• Operator Training.

PHASE 6 - Practical Lean and Flow Implementation

Product Team Activities
• Driving the Process to Demand.
• Material Kanban Management ( “f” inventory strategy).
• If necessary adjust the " f ".
• Mix Model Performance.
----- Linearity calculation
----- Flow rate
----- Audit of CT
----- Audit of Lead Time
• Confirm Kanban organization.

Process Team Activities
• Audit of Lean & Flow Line performance.
• Audit of Mix Model performance.
----- Productivity
----- Quality
----- Lead Times
• Employee training and implication.
• Define employee certification program.
• Define flexible employee plan.
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