LEAN MANUFACTURING

“Lean transformation” is a fashionable term lately, but its power is clear to those who know examples of Toyota’s efficiency, or the effects of implementing optimization programs like Porsche, Boening, etc. As a result of implementing our plan, or one developed in cooperation with us, the Client can expect, first of all, a shortened lead time, from the customer’s order, providing means for production and delivery through optimization of logistics and production processes. The example of the aforementioned Porsche shows that a well-developed and implemented program allows for a several-fold shortening of the time of implementing a new product, saving space and reducing production costs by over 30%.

Our team consists of specialists who gained their experience in leading global corporations, including automotive ones, familiar with all production processes – stamping, welding, assembly, injection molding, extrusion, etc.

We optimize logistics, production and administrative processes based on world standards – TPS, Lean Manufacturing, WCM:

  • We support the implementation of new products, customers, suppliers, production lines, and engineering changes.
  • We conduct audits to identify losses – Muda – caused by inefficient processes. We develop repair programs tailored to the Client’s expectations and support their implementation:
    • Value Stream Mapping (VSM) across the entire supply chain (from supplier to customer)
    • Balancing production lines (Yamazumi, SMED, etc.)
    • Automation of production processes and product control/validation (Traceability, Pokayoke, Go/Not go CF, etc.)
      We conduct training in process monitoring, problem solving and optimization aimed at building a Continuous Improvement culture in the company.

As part of the post-audit action plan/at the Client’s request, we design, manufacture and implement modern loading/reloading and storage systems and deliver components to production lines in accordance with the JIT principle, limiting stocks – reducing logistics costs in the enterprise

  • Customized trailers for transporting components and products
  • Shelves and warehouse equipment
  • Dedicated packaging and protection of components/products
  • Pick-to-light systems and markets
  • Semi-automatic and automatic transport systems from warehouse to production lines

As part of the optimization of production processes, we offer design, production and implementation of:

  • Go/not go CF
  • Industrial automation
  • IT systems for managing component deliveries and the production line
  • Design, implementation, and operation of IT systems supporting logistics and production processes, as well as integration with existing enterprise systems