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trans·for·ma·tion
/ˌtran(t)sfərˈmāSH(ə)n/
noun - a thorough or dramatic change in form or appearance
We bring expertise, experience, and tools to plan and implement the transformation journey with you on the shop floor.
We measure our success on the actual results delivered to our clients
Transformation is deployed through a structured and tested approach
PEOPLE
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PROCESS
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CULTURAL SHIFT
RESULTS
SYSTEMS
PEOPLE
People are the greatest asset of any company. We evaluate the management structure, span of control, skillset, and deliverables to provide practical and effective management solutions.
Our consultants train your staff on effective leadership and management skills, lean six sigma continuous improvement techniques, and operations flow management while working with them on the floor. This enables your team to conquer the next challenge and build continuous improvement culture as part of your organization's DNA
PROCESS
Robust processes are a prerequisite to being a world-class manufacturer. Robust processes deliver stable outcomes and have SIC (short interval controls) to surface the problems quickly if they arise.
We work intensively on the inputs tracking, analysis, improvement, and control so the outputs are consistent all the time. We use lean, six sigma, and TOC to create flow, reduce variation and remove bottlenecks.
SYSTEMS
Systems are an integral part of shop floor management and improvement as they provide live view of the performance, job and order tracking. The data is stored in the cloud to automatically generate trends and opportunities for improvement. Some of the systems we create and deploy are:
Andon System - Operator and leader view
Dashboards - One-Stop Information Shop
Job & Order tracking
Thruput and Efficiency
We help the clients manage length and breadth of emotional change cycle
Align Direction
Goal Setting
Reduce Frustration
Communication
Spark Motivation
Quick Wins
Develop Capability
Training
Share Knowledge
Standardization
Drive Ownership
Reward
Our pragmatic transformation model has delivered results consistently
BUILT FOR LASTING SUCCESS
DIAGNOSE CURRENT STATE
We assess the current situation to understand challenges, opportunities, and strengths. The situation is assessed by observing processes/flow, conducting interviews, and data analysis. It takes 2 to 8 weeks to conduct a current state assessment depending on the scale and scope of the plant.
PLAN FUTURE STATE
We create a clear path forward with tangible milestones, clear timelines, and significant outcomes. The future state is built by leveraging quick wins to create momentum for sustainable results over the long term. We build a clear winning strategy for our clients that focuses on people, processes, and systems so the team moves forward in balance.
STABALIZE OPERATIONS
Stabilizing a plant to deliver predictable and consistent output is one of the most critical steps in transformation. We stabalize key inputs stabilizing staffing, operational processes, quality, maintenance, and supply chain logistics to get consistent output every shift everyday.
MAKE INVENTORY FLOW
Capacity is matched with demand and the schedule is level loaded so the variations are reduced. Visual factory plays an important role in creating flow as sWIP targets are set, Andon clocks are implemented, and inventory flows FIFO. Raw material and finished goods flow is aligned with production planning.
IMPLEMENT TAKT & PULL SYSTEMS
Closed-loop reporting and improvement methodology is implemented. Daily, weekly and monthly dashboards are created and meetings are scheduled to understand issues, conduct RCA, and implement corrective actions. This forms the PDCA cycle of improvements
SUSTAIN THE IMPROVEMENT & RESULTS
We believe growth and improvement journey is filled with step and incremental changes. True progress comes only when the gains are sustainable and the new state becomes a true baseline to future state.
