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08/18/2011 10:30 AM
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Good afternoon,
I'm a consulting for 20 keys(r) a High Performance Systems in Italy. So for the moment I have worked a lot in mechanical industry were I have a good experience in VSM but I have not experience in application of VSM in process industry. the statu of this company are:
- the product is a commodity and they sell the product directly to big retailer like a Carrefour, Tesco, Wolmart
- they recive from buyer some sales forecasts
- the process are easy they have a supplier with 17 different material anddifferent lead time
- they have 3 different lines and the are working for the warehouse
Please can you suggest where I can start in order to define the best setup of VSM, how we can define the takt time, pitch, process pacemaker, leveling of production?
thank you for you contribution.
Best Regards
Gigi
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08/19/2011 06:23 PM
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Dear Gigi,
In my opinion the Lean Culture can be applied in any
field both Mechanical Industry and Process Industry.
By the way I suggest you to identify with the rule of 20/80 the
20% of product that generate the 80% of the revenue and start
with this line.
As you told you have to start with the takt time for this line and VSM for this line.
On the shopfloor start with 5S.
For takt time simulation on line you can use this website
http://www.leanlab.info/?lang=en
.
Edited: 08/19/2011 at 06:23 PM by Lean Moderator
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08/26/2011 03:34 PM
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Hello Gigi,
I also work in a process industry. Marco is right that there are many overlaps between mechanical and process manufacturing and you're right that sometimes the application feels slightly different. We have had the most success when using a vsm to highlight our bottleneck step then do a process step vsm to undercover more opportunities. 5S, although useful, is not the big bang tool for us since everything is a monument and our process isn't manual. Communication flow is a problem as well as non standardized jobs. How about SMED techniques applied to routine maintenance jobs? Raymond Floyd's Liquid Lean book offers nice insight into the similarities and differences of mechanical and processing manufacturing.
Best of luck,
Kelly
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08/30/2011 10:25 AM
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Hi Gigi
Start by determining their product families and grouping the products accordingly, that should start to show you what to map.
Robert Drescher
ELSE Inc.
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Note: These forums are moderated by the Lean Enterprise Institute. All posts are reviewed prior to appearing on the site. Views expressed in these forums do not necessarily represent the views of the Lean Enterprise Institute.
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