Safety, Health & Environmental
Have you achieved zero accidents and sustainable energy and environmental efficiency? Tools and programs available are Incident/Injury prevention, Behavior Based Safety, Safety Training and Successful Safety Committees. Industrial Health programs (chemical exposure, noise, etc) and Energy and Environmental programs.
Higher skilled, multi-skilled jobs are demanding better Pre-hire and Selection processes, New Employee Onboarding, OJT qualifications, Certifications and Recertification. This dimension also addresses Adherence to work rules and policies and procedures. Attendance, Break Periods, Drug & Alcohol and valuing the individual Best Practices. Become the Employer of Choice.
Process Effectiveness & Control
Effective use and application of process discipline and control will lead an organization from high cost and poor quality to consistency, then statistical control and finally continuous improvement. Tools and applications used in this dimension is Standardized Work, Standard Operating Setpoints, Change Control, ISO, 6-Sigma (SPC), 8-D approach, DMAIC, PFMEA and Experimental strategies.
Process Simplification and Lean Processes
Focus on the Value Added Processes and eliminating waste improving cycle time. Value Stream Mapping, 5S, Visual Management (Kanban), Level Loading, Kaikaku Events, Standardized Work and Set-up Reduction. Maximize labor efficiency and asset utilization while minimizing work in process.
Key Performance Indicators that that provide timely, relevant information for all team members that encourage continuous improvement activities. Metrics should drive behavior change and have direct correlation to Safety, Cost, Quality and Delivery.
Product & Process Innovation
Getting high-quality new products to market on time is one of the most crucial aspects for a business. Tools include New Product Gate Process, how to Screen and Prioritize New Product Projects, conducting Market Validations and Competitive Analysis. Developing a Market Launch Plan and accelerating the manufacturing integration process with Design for Manufacturing.
Supply Chain Management
Building a competitive infrastructure, leveraging worldwide logistics, synchronizing supply with demand and measuring performance globally. Tools used are Vertical Integration/Out-Sourcing (Make vs Buy Analysis), Vendor Managed Inventory, Just in Time supply chain logistics.
Are your information technology systems providing the information that you need? Are they integrated? Facilitation of selection of the proper Manufacturing execution systems (MES), Warehouse Management Systems (WMS), Maintenance Management Systems (MMS), Human Resource Systems (HRS), Learning Management Systems (LMS) that your business needs.
Leadership & Communication
For Executives, Senior Managers, Plant managers and Plant Staff. Developing Mission, Vision and Values. Goal Setting & Objectives. Team Building events. Plant turn-arounds and mergers. Some of the tools used are Toyota Kata Managing for Continuous Improvement, The 4 Disciplines of Executions, SWOT and Employee Climate Surveys.