Upload
leansoftrus
View
27
Download
1
Embed Size (px)
Citation preview
«Visual Lean» service overview –IT-solution for monitoring
the development of production system based on Lean
IT-SOLUTIONIN LEAN
Innovative CompanyThe company is founded by a group of experts - supporters of Lean philosophy to develop IT-solutions.
2012October
Nizhny Novgorod IT-park residentsSuccessfully passed the regional innovative projects selection and opened the first office in Nizhny Novgorod.
2012November
IT-SOLUTION IN LEAN LEANSOFT HISTORY
Version 2.0 of Visual LeanDevelopment of new functional features. Development of new services in the field of Lean manufacturing.
2014January
Visual Lean LaunchVersion 1.0 of Visual Lean web-service in Russia. The first pilot projects are launched.
2013May
2013 November
Kazan IT-park residentsSuccessfully passed the regional
innovative projects selection. Opened the office in Naberezhnye Chelny.
PartnershipEstablished collaboration with Kaizen Institute and
Lean Center “Prioritet” 2014April
International contestThe company has become the general
partner and the organizer of the international competition
"For leadership in Lean - 2014"
2014January
2014February
Key customers
2015June
Project “Visual Lean” is winner of the contest “IT-Volga” by Skolkovo Foundation
2014September
Technopark “Skolkovo” residentsLeanSoft became resident of Technopark “Skolkovo”.
2015 -2016
Key customers
Version 3.0 of Visual Lean
Development of new functional features. Development of new services in the field of Lean manufacturing.
2016September
• How to improve employee engagement in continuous improvement process?
• How to monitor every department on Lean conformance in a quality and timely manner?
MAIN ISSUES IN IMPLEMENTING LEAN
• How to reduce wastes performing Lean audits on a regular basis at all the departments of the company?
• How to draw attention of personnel to the gaps in their knowledge of Lean and encourage them to educate themselves in this area?
®
PROBLEMS SOLUTION
Audit Tracking System
SOLUTION IS IN USING OF SPECIALIZED INTERNET-SERVICE
The «Visual Lean» service facilitates the work of auditors and automates monitoring of improvements in Lean towards perfection.
«VISUAL LEAN» SERVICE DESCRIPTION
• Carrying out weekly internal audits in the area of Lean manufacturing at all the departments of the company;
• Generating the Waterfall charts using the results of every passed audit;• Generating trends showing the level of implementation of Lean philosophy, principles and
tools at all the departments in real time;• Generating and printing reports online;• Tracking the audits status (how many planned audits have already been conducted at the
moment)• Performing cross-check audits to identify incorrect information• Providing support information on all the questions of a checklist
Main functions of the «Visual Lean» service
PROCESS OF PRODUCTION SYSTEM IMPROVEMENT USING «VISUAL LEAN»
Analyze the audit results and trends in the servicePrepare the weekly plan for
improvementsWork on improvementsCarrying out all audits in the service
Creation of the enterprise structure and users in the
«Visual Lean» service
weekly
HOW TO START USING «VISUAL LEAN» SERVICE
1. Create a profile and the structure of the company, which will be used for monitoring of production system development.
2. Create «Visual Lean» users and add their personal details.
3. Assign users to the departments and define their roles in the «Visual Lean» (Manager, Auditor, Trusted Auditor)
To start an assessment using the IT- service «Visual Lean», it is necessary to perform the following actions:
Компания
Division №1 Division №2 Plant/shop №1 Plant/shop №2
Tree
leav
esTr
ee n
odes
Departments
To start using the «Visual Lean» service, it is necessary to create the structure of the company in the form of a tree, where: • Tree root is an enterprise or company• Tree nodes are companies, divisions, plants, shops, etc. The assessment of tree
nodes is based on the assessment of tree leaves. • Tree leaves are the departments to be assessed. Assessment is performed only at these
departments.This structure will be used in the course of the assessment and calculation of results.
SET MONITORING COMPANY STRUCTURETr
ee ro
ot
Enterprise/company
Departments Departments Departments
FIRST NAMELAST NAMEPHONEEMAIL
ADDING USERS
FIRST NAMELAST NAMEPHONEEMAIL
FIRST NAMELAST NAMEPHONEEMAIL
User accounts must be created for all users of the «Visual Lean» service who are going to use it for monitoring of the production system development.
AuditorsManagers Trusted Auditors
Tree
root
Manager Manager Manager Manager
Tree
leav
esTr
ee n
odes
USERS AND USERS’ ROLES ASSIGNMENT
ManagerTrusted auditor
Auditors Auditors Auditors Auditors
To use the service, it is necessary to assign users with clearly defined roles for every department in the company structure. Roles available: 1. Auditor – fills in the checklists;2. Manager – analyses visualized audit results and reports;3. Trusted auditor – conducts an expert assessment of the
departments with significant deviations.
AUDITORSConduct weekly internal audits on their departments
TRUSTED AUDITORSConduct an expert assessment of the departments with significant deviations
LEAN PHILOSOPHY3 CHECKLISTS
LEAN TOOLS12 CHECKLISTS
LEAN PRINCIPLES4 CHECKLISTS
HOW AUDITORS WORK
Lean Philosophy ( 3 checklists )• Meeting the material needs of a person;• Meeting the professional needs of a person;• System of management and control based on Lean philosophy.
Lean Tools ( 12 checklists )• Total productive maintenance (ТРМ); Single-Minute Exchange of Die (SMED);• Value stream mapping (VSM); Production smoothing (Heijunka);• Standardization; Built in Quality; Wastes analysis; “5S” System;• Andon system; Kaizen; Kanban; Visualisation.
Lean Principles ( 4 checklists ) based on 14 principles of The Toyota Way• Long-Term Philosophy;• The Right Process Will Produce the Right Results;• Add Value to the Organization by Developing Your People;• Continuously Solving Root Problems Drives Organizational Learning.
LIST OF CHECKLISTS
YES
“YES” answer is put, if the described
requirement is being fully executed.
“NO” answer is put, if described requirement is not being executed at all or partially executed, or the respondent does not understand
what is being asked about.
All the questions in checklists are divided into two types:• “Yes-No” questions. The number of such questions amounts to 85% of all.• “Open” questions. It is necessary to point the number of work places that meet certain criteria.Such questions allow to reduce the influence of human factor when conducting an assessment.
TYPES OF QUESTIONS IN THE CHECKLISTS
NO
Data from all checklists of every department should be input to the service once a week. Upon completion of the assessment, the IT-service calculates the results automatically, introduces appropriate amendments to the scores for companies, divisions, plants, departments and so on and generates a ranking. All the findings instantly become available for the management of any level depending on access right.
Start new audit and download the blank
checklist
Answer the questions in the checklist
Enter answers into internet
service
Complete audit and get results (rating, charts,
reports)
INTERNAL AUDIT PROCEDURE
Line chart
Bar chart
Radar chart
Pie chart
Waterfall chart
GRAPHIC TRENDS (Line charts)Provide visual information about the development of the company’s production system based on philosophy, principles and tools of Lean production.
DIAGRAMS AND CHARTSAllows to get a visual information about:• Level of implementation of the
philosophy, principles and tools of lean manufacturing,
• Bottlenecks identified using various Lean criteria.
DATA VISUALISATION
TYPES OF MANAGER’S REPORTS«Visual Lean» service automatically generates reports for selected departments about the results of passed audits for a selected time period
• REPORT ON AUDIT RESULTS FOR A SELECTED DEPARTMENT GROUPED BY CHECKLISTSContains assessment results for every checklist only for a selected department with an indication of the percentage of passed audits. The results are grouped by checklist.
• REPORT ON AUDIT RESULTS FOR A SELECTED DIVISION/PLANT/SHOP GROUPED BY LEAN AREASContains assessment results for all passed in a selected division audits. The report includes the names of departments in division and results for every department. The results are grouped by Lean areas: Philosophy, Tools, Principles.
• REPORT ON PASSED AUDITS FOR SELECTED DIVISION/PLANT/SHOP/DEPARTMENT IN TABLE VIEWContains assessment results, which are displayed in the table. Results are displayed for every department for every checklist with an indication of persons who are responsible for audit on every department.
FIND PROBLEM
Based on the results of passed audits
employees find bottlenecks and put
them into the online-Service.
ASSIGN EXECUTOR
Assign the problem to any employee-user
who will be responsible for its
resolution.
TRACK STATUS (CHANGES)
Track the resolution status of found problems, e-communicate with executers and make
necessary changes into the online-service.
IMPLEMENT SOLUTION
Close problems, when they were resolved and
solutions were standardized in the
company.
PROBLEMS TRACKING
QUALITY MORALECOSTDELIVERYSAFETY
S Q D C M
IDENTIFYING PROBLEMS BY CATEGORIES
INFOGRAPHICSGRAPHIC TRENDS
CHARTS TABLES
Dashboard displays the key data for every department or group of departments or across the enterprise. Any manager can quickly find the information, indicators, results he needs.
DASHBOARD
KEY CUSTOMERS
5 REGIONS
24COMPANIES
33552AUDITS
11CITIES
ORGANIZERInternational Public Organization for Development of Production Systems Based on Lean Principles and Philosophy
«FOR LEADERSHIP IN LEAN - 2014»INTERNATIONAL COMPETITION
GENERAL PARTNERLeanSoft Company
«Visual Lean» Service was used by the contest organizers as the main platform for evaluation of production system development of the participating companies based on Lean principles and tools.
ORGANIZING INTERNAL COMPETITIONSKAMAZ GROUP COMPETITION «PSK LEADER»
«Visual Lean» Service was used by the competition organizers as the main platform for evaluation of production system development of the KAMAZ group divisions based on Lean principles and tools.
ORGANIZERKAMAZ Production System Development Committee
ADVANTAGES OF USING «VISUAL LEAN»• Ready-made, single for the entire team
method of estimation and calculation of results, based on measurable indicators;
• Common Information Space;• Automatic calculation of results and online
current rating of participants;• Accessibility, transparency and visualization of
results;• Staff Involvement in the process of
continuous improvement through participation in an internal competition using «Visual Lean» service.
PROJECT DURATION 8 months
NUMBER OF COMPANIES
22 companies
NUMBER OF DEPARTMENTS
932 items
NUMBER OF USERS
1054 persons
EXPERIENCE OF IMPLEMENTATION - KAMAZ
INVOLVED STAFF21 000 employees
PASSEDAUDITS
97830 items
PROCESSED USERS REQUESTS458 items
AVERAGE LEAD TIME PER REQUEST
1 day
EXPERIENCE OF IMPLEMENTATION - KAMAZ
LEAN PHILOSOPHY
+10%
LEANTOOLS
+9%
LEANPRINCIPLES
+12%
GROWTH INDICATORS BY AREASFOR 5 MONTHS*
*according to “Lean Manufacturing. Winners Technologies.” magazine. Issued by KAMAZ. Issue №2, April 2016.
To optimize costs of input control and be sure in delivery quality, a customer should help to develop production systems of its suppliers based on Lean methods and tools.
SUPPLIERS DEVELOPMENT
To establish trusting relationships with suppliers, a customer may ask them to regularly self-assess their production system and share the results.
It is possible to do it using «Visual Lean» service.
The customer will see the development of the suppliers’ production systems and any issues identified in real time and will be able to help the suppliers address them on time. Using this service the customer will be able to highlight any deviations, which the supplier needs to eliminate.
Kaizen Tracking System
Service helps to record, control and track the status on implementation of Kaizen suggestions and Kaizen projects. “Kaizen” serves to involve personnel into the CIP process, accumulate the common company-wide expertise base, and replicate successful experience. Employees can enter data on their Kaizen suggestions and their application in practice into the system. Both effective improvements and improvements, which didn’t give a positive result, are sent to the expertise base and stored in the system.
Common expertise base helps the employees, who are located remotely from one another, to share openly and adopt experience, apply already proven effective improvements and refrain from testing the improvements, which weren’t effective on the other areas. All the data in the expertise base are systematized enabling quick retrieval of data and saving much time and resources due to the two-way communication between the key players on any Kaizen suggestion put into the system.
SOFTWARE UNDER DEVELOPMENT
Standard Operating Procedure
Specialized terminal with pre-installed IT-solution enables automation of the input and output of standard operating procedures (operating instructions) and leveling with the help of Yamazumi chart. The software will significantly speed up the document flow, allowing all the users to be aware of all the changes online. It is an automated and multipurpose system where you can create, record, store, or get approvals of electronic manuals. This system will help to increase labor productivity of manufacturing engineers and workers by reducing the time necessary for documents development, amendment and approval.
• Fast creation, editing and agreement of SOP• Automatic synchronization between the charts when making amendments• Quick creation of spaghetti chart• Quick filling in of visual safety guidance • Simple adding and editing of graphic image of operation• Storage of revision history in SOP, quick search and sorting• Informing the stakeholders online about changes in SOP
Main Service functions
Interactive Learninig System
The service is designed for staff training on Lean production.
Knowledge base contains: glossary of terms, descriptions of theoretical and practical skills for application of methods and tools of Lean production, step-by-step guide on addressing the problems identified.
This service will make it possible to certify personnel for knowledge of Lean and create employee training and refresher training programs.
The service will allow creating teams inside a company, engaging suppliers and training them online.
Service will allow to either conduct training inside the company for own personnel or engage suppliers and train them online.
www.lean-soft.ruvisuallean.ru
@lean_soft
Naberezhnye Chelny, Mashinostroitelnaya, 91IT-PARK+7 (8314) 144-844
Nizhny NovgorodRodionova street, 192 D ,+7 (8314) 144-844
Thank you!