Lean 4.0

• Defining, designing, and implementing sources of data: Identifying, designing, and establishing various data sources that will be used to collect relevant information. This involves determining what data is needed, how it will be collected and stored, and how it will be accessed.

• Flow design and implementation: Creating a smooth and efficient process for moving the data through the different stages, from initial collection to storage, processing, and analysis. This ensures that the data is effectively transferred throughout the system.

• Creating a data lake: Establishing an infrastructure or environment that is suitable for storing large volumes of data in a secure and accessible manner. This "data lake" allows data to be centralized and organized, facilitating its analysis and use.

• Modeling indicators for decision-making: Developing specific models and metrics that will be used to evaluate performance and provide key information for the decision-making process. These indicators are based on the collected and processed data.

• Determining automated decisions: Implementing automated systems or processes based on predefined rules or algorithms that use data and indicators to make operational decisions. This enables quick and efficient responses to specific situations without direct human intervention.

• Designing and implementing the S&OP (Sales and Operations Planning) model: Developing and implementing a comprehensive process that integrates sales and operations planning to better coordinate demand and production capacity. This model ensures closer alignment between the sales, marketing, finance, and operations departments.

• Planning and scheduling model: Creating a detailed model for scheduling activities within the company, enabling better coordination of resources, time, and activities. This may include optimizing the production schedules, the allocation of resources, and inventory management, among other aspects.

• Designing the capacity plan tool: Developing a specific tool for planning the production capacity, taking into account available resources, projected demand, and other relevant factors. This tool helps optimize the company's operating capacity.

• Implementing the MRP (Material Requirements Planning) / MPS (Master Production Schedule) / FCE (Finite Capacity Scheduling) models: Implementing specific computer systems or models for material requirements planning, master production scheduling, and finite capacity scheduling. These models help to efficiently manage the company’s materials, production, and available resources.

• Line balancing and work design: Process aimed at efficiently distributing tasks and activities among the workers and workstations, with the objective of minimizing bottlenecks, maximizing productivity, and reducing waiting times.

• Time and task studies: Detailed analysis and accurate measurement of the time required to perform each task or activity within a process. This involves carefully studying the work methods, the time required to complete a task and the employees’ performance.

• Constraints analysis: Identifying and evaluating the limiting factors or restrictions within the company’s production processes or operations. These may be limited resources, insufficient capacities, or any other factor that hinders efficiency.

• Layout redesign and defining the CAPEX: Reorganizing the physical design and distribution of the elements within a plant or workspace to improve efficiency and optimize workflow. Defining the CAPEX (capital expenditure) refers to identifying and budgeting investments in long-term assets, such as machinery, equipment, or infrastructure, that are needed to implement design changes and improve efficiency.

• Designing and implementing high-performance teams: Creating and implementing teams that focus on maximizing their performance and productivity. This involves identifying complementary skills, managing conflicts, and ensuring effective collaboration and motivation to achieve optimal results.

• Configuring new operational templates: Developing and establishing new formats or operational structures that are better adapted to the company's processes in order to improve efficiency and the quality of the work.

• Floor control model: Implementing a real-time supervision and management system in the production area or on the work floor, enabling the operations to be continuously monitored and the ability to intervene quickly if problems arise.

• Implementing automated indicators and dashboards: Developing and implementing key metrics to measure performance and productivity that are then presented through automated dashboards that provide real-time information on the status of the processes.

• Implementing an Innovation Hub: Creating a space or platform aimed at fostering creativity and innovation within the company. This "Hub" facilitates the generation of new ideas, experimentation, and the development of innovative projects.

• Coaching and development model: Establishing a structured coaching and development program to improve the personnel’s skills and knowledge, promoting their professional and personal growth within the organization.

• Preventive and predictive maintenance model: Developing and implementing a structured approach to maintaining the equipment and machinery in optimal conditions. Preventive maintenance focuses on scheduled inspections, cleaning, and replacement of parts to prevent failures. Predictive maintenance uses technology and data to predict potential failures so that actions can be taken before they occur.

• Implementing control software: Adopting and integrating systems and specific digital tools for maintenance control and management. This software can help with maintenance scheduling, task tracking, spare parts inventory management, and equipment status reports.

• Strengthening the maintenance routines: Strengthening and improving existing practices in the maintenance process. This may include reviewing and optimizing procedures, strengthening the training provided to the personnel involved, and implementing stricter standards to ensure that the maintenance work is carried out efficiently and consistently.