lean ofis presentation
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Operational Excellence Solution Provider
Work for your excellenceWork for your excellencewww.leanofis.com
Lean Ofis : Operational Productivty in Manufacturing
What we do for your excellence ?
Lean Transformation Manufacturing System Design Lean Innovative Engineering
Lean Operations Management system implementation.
Flexible manufacturing system design & implementation with tubular system.
Design and develop smart solutions for montage, poka & yoke and testing process needs.
Operational Excellence ( OpEx)
Work for your excellence
Operations Management System Design
• Assessment of the plant• Current State / Future state VSM• Strategic Road Map for improvement• Implement latest lean tools• Change the culture• Develop Lean Leader
Production Cell Design
• Work stations• Supermarkets• Special Trolleys and flow racks• Warehouse Storage systems• Visual Inform. & Commu.Boards• Andon Systems
Production Machinery Design
• Montage process machines• Montage poka & yoke machines• Test process machines
• Hot melt machines and applications
Productivity Flexibility Capability
Lean Ofis : Operational Productivty in Manufacturing
Road map for operational excellence….
5S
VISUALMNGMT
STANDARD
KAIZEN PULL
FLOW
HEIJUNKA
SMED
QAN
JIDOKA
POKA & YOKE
PDCA
TPM
QRS
PERF. MNGMTİ
P&L
LEANORG
Assesment
VSM
Road Map
Lean Transformation
Work for your excellence
SMED PDCA
Manufacturing System Design
Work Stations SupermarketsSpecial Trolleys
Visual Inf. Boards
Andon Systems
Lean Innovative Engineering
Montage Machines
Poka & Yoke Machines
Test Machines
Operational Excellence & Culture Transformation
Lean Ofis : Operational Productivty in Manufacturing
1- Lean Transformation
�� Operational processOperational processss assessment with 17 categoryassessment with 17 category
�� Current State Analysis ( Value Stream Mapping)Current State Analysis ( Value Stream Mapping)
�� Future State AnalysisFuture State Analysis
Lean Ofis implement latest lean tools into your value stream by doing workshopapplications in GENBA together with know-how transfer in the area of LeanOperations Management.
Work for your excellence
�� Future State AnalysisFuture State Analysis
�� Kaizen Game plan ( Improvement Road MapKaizen Game plan ( Improvement Road Map))
�� Implementation of Lean Tools for operational ExcellenceImplementation of Lean Tools for operational Excellence
�� Work Place Organizations ( Standard , 5S, Visual Management)Work Place Organizations ( Standard , 5S, Visual Management)
�� Establish continual flow ( Pull system, Establish continual flow ( Pull system, KanbanKanban, SMED, Supermarket), SMED, Supermarket)
�� Implement Quality Assurance Network ( Implement Quality Assurance Network ( JidokaJidoka, , PokaPoka & Yoke)& Yoke)
�� Implement TPM and quick response system for operational Implement TPM and quick response system for operational availabilityavailability
�� BenBencchh marking for operations managementmarking for operations management
Lean Ofis : Operational Productivty in Manufacturing
1- Lean Transformation
Lean Ofis perform detailed assessment analysis to understand the operationalexcellence maturity and create strategic improvement plan for development.
( Hoshin Plan)
Work for your excellence
Lean Ofis : Operational Productivty in Manufacturing
Lean Ofis perform detailed assessment analysis to understand the operational excellencematurity and create strategic improvement plan for development. ( Hoshin Plan)
1- Lean TransformationWork for your excellence
Lean Ofis : Operational Productivty in Manufacturing
Lean Ofis Implement latest lean tools into value stram by doing analyze and application togetherwith the Plant Team in order to establish operational standards in all area of the chain.
Stop @ Abnormality
Pull Production
LEAN
1- Lean TransformationWork for your excellence
HeijunkaHeijunka
Six Six
SigmaSigma
Value Stream Map, 5S , Supermarkets , SMED
JIT Jidoka
Foundation
(VSM, 5 S, Standard, Supermarket, SMED)
JidokaJIT Kaizen
Abnormality
Takt Time Production
Single Piece Flow
Production
Autonomation
SequencingLevel Loading
Lean Ofis : Operational Productivty in Manufacturing
�� Material Handling Systems for Material Handling Systems for material flow and space optimizationmaterial flow and space optimization
�� SupermarketsSupermarkets
�� Flow rack trolleysFlow rack trolleys
Lean Ofis design and implement special and flexible smart solutions for theproduction cell. Tubular system (special pipe and connection items) provide flexibilityfor future engineering changes and capacity adjustments.
2- Manufacturing System Design with tubular systemWork for your excellence
�� Flow rack trolleysFlow rack trolleys
�� Warehouse storage Warehouse storage
�� Process flow configuration Process flow configuration system system
�� Single Work stations Single Work stations
�� Special tooling's equipped work stationsSpecial tooling's equipped work stations
�� U U shapeshape Assembly linesAssembly lines
�� Visual management and communication systems for Visual management and communication systems for information flowinformation flow
�� Special design panels and boards included necessary formSpecial design panels and boards included necessary form
Lean Ofis : Operational Productivty in Manufacturing
12
3
4
65
30
mm
2- Manufacturing System Design with tubular systemWork for your excellence
Lean Ofis : Operational Productivty in Manufacturing
2- Manufacturing System Design with tubular system ( samples)
Visual Management Clasical WS Flow Racks
Work for your excellence
Tailor Made WS Communication Area Supermarket
Lean Ofis : Operational Productivty in Manufacturing
�� Production Cell Machinery designProduction Cell Machinery design
�� Montage Montage PokaPoka & Yoke machines& Yoke machines
�� Test MachinesTest Machines
Lean Ofis design and implement special smart solutions for your machinery needssuch as poka&yoke machines, montage machines and test machines.
3- Lean Innovative EngineeringWork for your excellence
�� Test MachinesTest Machines
�� Special needSpecial needss equipmentsequipments
�� PlantPlant configurations configurations
�� Factory layFactory lay--out solutionsout solutions
Lean Ofis : Operational Productivty in Manufacturing
Verification /Verification /
QualificationQualification
PhsicalPhsical
DesignDesignProductionProduction
TechnologyTechnology
SelectionSelectionConceptConcept
DESIGN FMEADESIGN FMEA VERIFYVERIFY LAUNCHLAUNCH
3- Lean Innovative Engineering ( Process Flow)Work for your excellence
�Design Intent
�Customer needs
�Product requirement
Lean Ofis : Operational Productivty in Manufacturing
3- Lean Innovative Engineering ( Sample Poka & Yoke Machines)Work for your excellence
Lean Ofis : Operational Productivty in Manufacturing
Lean Ofis
The productivity has never become so important like today.
“More and more with less and less” is the main topic of all companies nowadays. How could thatbe achieved? Our answer, as Lean Office, would be “Operational Excellence”.
Increasing competition and recent economical crises in the world make productivity andefficiency in all business operations a major and critical issue for companies today. To be a goodexample not only in its field, but also in general in the business world,
�Operational processes and procedures must be designed thoroughly,�Development program for the employees must be followed,�Performance based and Lean management system must be applied,
Work for your excellence
�Performance based and Lean management system must be applied,
Lean office has been founded as a “change management and application” consulting company inAugust 2008, Istanbul, Turkey. A consultant who is appreciated in business world, who; Pushes thecustomer towards making progress and motivates them Assumes a leadership role on behalf of thebusiness owner Decreasing dependency of himself in time
As a principle in lean office rather than giving advice which is common in general consultancypractice, we implement the lean concept each and every processes in the operations.
Our mission is; to be a solution partner of our client in its operational excellence journey withimplementations in the field together with your people, while our Lean Ofis consultants transfertheir know-how and expertise, they also teach how to gain know-why culture when you are atwork.
Therefore, aiming customer intimacy and operational excellence in its consultancy services, Leanoffice is positioned itself much closer to you and your people while striving for the best all the time
Lean OfisLAG Danışmanlık ltd.Beyaz köşk sokak, No:15 / 134840 Küçükyalı - İstanbul
Tel 0 216 366 34 42Fax: 0 216 366 34 [email protected]
Lean Ofis : Operational Productivty in Manufacturing
Lütfi Apilioğulları
Lütfi Apilioğulları, MBA
Lean Ofis
Funder / Principle Consultant
Operations Management / Lean Six Sigma
Tel 0 216 366 34 42
Fax: 0 216 366 34 62
Mobile 0 532 253 43 36
Work for your excellence
Apiliogullari has built a successful career based on his enriched experience gained in automotive, telecommunication and electronics industries both in national and international companies. He worked in various positions in these industries as an engineering manager, manufacturing manager, operations director, Lean manufacturing coordinator and Plant Manager.
He worked together with Sensei's in the lean transformation and factory operations management a long time and has hands-on "Lean Six Sigma" experience in more than 350 kaizen applications in Turkey and abroad.
As an expert in the areas of Toyota methodology in plant management, advanced level Lean & Six Sigma applications and change management, Apiliogullari wrote a book "Lean Transformation / Code of Productivity" which will be published by Sistem Publications on February 2010.
He has Bachelors degree in Electrical Engineering, Dokuz Eylul University, Izmir and Master of Business Administration degree (MBA) from the same university. Apiliogullari is married with one children.
www.leanofis.com