Process Flow Optimization

Lean Transformation to reduce Operationnel Cost

Main Focus: Applying transformation Strategy in the leanway Appropriate Approch and Tools


Think Lean (Taiichi Ohno)

​All we are doing is looking at the time line, from the moment the customer gives us an order to the point when we collect the cash. And we are reducing the time line by reducing the non-value adding wastes.

Therefore, we need to focus on the value chain first. Let it ​flow without constraint to deliver on time the value at the best price, with the expected quality requirement.
For achieving perfection over time, continuous improvement strategy is required.

Do it lean

Draw the current state of the Value StreamIdentify waste and bottlenecks through all activities of the Value Stream Establish actions to build future state of the Value Stream (Ideal)Issue implementation plan of short and long term actionsMeasure and Adjust .Launch PDCA to trigger continuous improvement.

Lean Transformation Strategy

Diagnostic Tools (waste time tracking)

SpaghettiSpaghetti chart: Motion and Transport time loss 
Work Combination chart:
Assessment of Cycle time versus Takt-Time
Job leveling analysis to track loss in cycle time
WIP Level:
Running time and waiting time assessment
Waiting Time:
Assessment of down time and shortage
Process Performance
Quality Level:
Scrap and rework tracking
  Tracking causes of waste of time


Optimization Tools (KAIZEN improvement plan)

Visual Management: KPI’s and 5S
Kaban: Just in time and reduce WIP
Supermarket: To reduce waiting time
SMED: Reduce changeover time
POKA YOKE: reduce errors
Standard Work: To reduce cycle time
PDCA: Tracking of improvement progress

Transformation Approach

Station 1

Assembly 1: Hot insertion of a threaded bronze insert. for the final assembly of the two parts of the differential

Station 2

Assembly 2:  This assembly consists of mounting one shaft and a pinion on to the Body 1. This assembly is referenced as part 1

Station 3

Assembly 3: This assembly process consists of mounting one shat and a pinion on to body2. This assembly is referenced as part 2

Station 4

Assembly 4: This process assembly consists to hold together PART 1 and PART 2 including 2 additional pinions.

Station 5

Qulity control station: This Quality control is to confirm sustainabilty of the product

Drawing Current State

Data analysis: Velocity Evaluation

Data Analysis Monitoring

Future State: Improvement loops

future State: Improvement Implementation

Training Tool 1: Standalone Interactive Simulator for Manufacturing and Services

Training Tool 2: Muti-station Interactive Simulator for Manufacturing and Services