World Class Audit
In order for businesses to begin their ‘World Class Manufacturing and Services’ (WCMS) journey they need to identify their current position benchmarked against local and international standards.
Audits are used to identify ‘quick wins’ and focus areas.
- World Class Manufacturing & Services (WCMS) audits are conducted over two (2) days covering 12 elements from goal clarity to operations and performance. The process involves employee interviews and workplace inspection resulting in a laminated report and video presented to all stakeholders during the feedback session.
- Cost of Non-Conformance (CONC) audits quantify areas of non-conformance by department and using the Parato principle indicates corrective actions required for the greatest improvement and most immediate reduction in waste.
- TPM readiness survey focuses on TPM specific areas and prioritises the type of activities required during a TPM intervention. This forms part of the planning phase of the process and is repeated at various points during the full intervention.
- Plant Maintenance Audit is used to create a benchmark for organisations wanting to compete at international levels of manufacturing competitiveness.
This popular 2 day Teamworks workshop is usually run off site over a weekend to avoid interference with productivity. Workshop content and processes are adapted to suit the specific team and cover elements such as value chains, trust exercises, team dynamics, developing mission statements, goal setting, meetings and action plans. Over 500 workshops have been run in 32 companies based in Africa and Europe.
Workplace Organisation (5S)
The 2 day Workplace Organisation intervention uses a 5 step approach, which goes beyond simple housekeeping to provide the basis for a variety of improvement systems such as the ‘Red Tag System’. The intervention includes revitalising the workplace, operator’s learning about 1st line maintenance, establishing goal sheets and refining ‘green area meetings’ and developing visual communication boards. Immediate results are reduced unplanned stoppages, improved performance and employee empowerment.
Back 2 Basics (LDT)
The practical Back 2 Basics intervention creates self-directed work teams and empowers them to identify, document and teach best practices through ‘Learner Directed Training Modules’ and ‘One Point Lessons’. Modules include process mapping, Skills and knowledge audits, documenting equipment and operational knowledge, 1st line maintenance, improve performance through quality and performance measurements, basic problem solving and RCA and basic coaching skills. The result is an operating manual showing current ‘Best Operating Practice’ created by empowered teams focused on continuous improvement.
Autonomous Maintenance (TPM)
Autonomous Maintenance is a concept unique to TPM and involves raising machine operator skill levels by encouraging and training them to undertake daily basic machine care, releasing skilled personnel to focus on equipment improvement and preventative maintenance. Teams will be led through the 7 step program towards the TPM goals of ‘zero breakdown, zero accident and zero defects’. A pilot project and team will be selected to initiate the intervention.
This 2 day practical SMED intervention covers the theory and techniques of performing set-up operations and changeovers in under 10 minutes. High performance teams will develop a ‘best practice’ map and benchmark for each changeover and identify and document equipment and process improvements. Performance measurements (OEE) will be used to identify focus areas for additional performance improvements. The quick changeover program guarantees immediate reduced waste and higher throughput.
Measurements and Mapping
The 1 day Measurements & Mapping (OEE) workshop teaches teams to how use Overall Equipment Efficiency measurements not only to measure the efficiency of their equipment but to also identify improvement areas. The BOB chart allows them to continually challenge their own performance and those of others via the visual management boards.
The 2 day Problem Solving workshop is a 5 step common sense approach to discovering the root cause of a problem and implementing sustainable countermeasures, involving all team members. Teams will identify and evaluate problems in the workplace and implement countermeasures to erase or reduce the root cause. Results are documented with continuous improvement ideas.
The Visual Management Techniques process is combined with ‘green area meetings’ and is used for effective communication between teams, shifts and departments. Teams are trained and empowered to create and manage their own communication boards and visual controls both in their workplace and on their equipment.
AfriLean offers 5 different LEAN Sales workshops designed to enhance the sales process by linking LEAN principles and systems to the 5 step sales approach. The result is a customer centric sales process, which focuses on greater efficiency and the continuous improvement of customer value. This customer centric approach eliminates waste both for the customer and the company through value stream mapping.