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Process Expertise | Lean Manufacturing

The companies search for profitability is driving the implementation of agile methodologies based on the principles of continuous improvement.

Manufacturing companies face the challenge of constantly verifying their processes to guarantee efficient operations, optimize costs, ensure product quality and achieving excellence in service.

With these efforts of continuous improvement and with the objective of increasing productivity, London Consulting provides support to its clients in the synchronization of their strategic objectives with the operations of the plant.

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The Challenge

This manufacturing model requires not only the modification of production techniques to reduce waste and optimize resources, but also it is necessary to implement a culture of continuous improvement in production lines and jobs. Communication and teamwork are fundamental for this method to suit every opportunity in the organization.

Some of the areas of opportunity that we have worked together with our clients for the successful implementation of this model are: lack of planning aligned to the demand and purchase system, possible underutilization of machinery or over production, absence of defining the adequate amount of human resource, poor floor control and maintenance planning and lack of control of quality assurance, among other factors.

Solutions

Production Planning


  • Calculation method for projection and determination of production standard times.

  • Calculation and design of tools to generate the production plan.

  • Decision tree for optimal sequence.

  • Master plan to redistribute work loads.

  • Mechanisms for effective coordination between the areas involved in the operation.

  • Design of the typical day for the production planner.


Floor Control


  • Active supervision model.

  • Tour of the machines detailing the status of condition of each.

  • Design of floor control tools.

  • Definition of indicators for production control such as OEE (Overall Equipment Efficiency), waste, compliance with the plan, etc.

Maintenance


  • Preventive maintenance plan.

  • Development of life sheets per piece of equipment.

  • Definition and update of standard times for execution, control and follow-up.

  • Setting parameters for replacement inventory levels.


Quality


  • Alert system that detects deviations of quality during production.

  • Definition and update of standard times, frequency and quantity of analysis for its execution, control and follow-up.

Benefits

Production Planning


  • Optimization of the use of machinery.

  • Visibility of the compliance in the level of service provided to clients.

  • Production plan and program matching raw material inventories.

  • Optimization of staff/personnel by adjusting it to demand seasonality.

  • Improvement in the coordination of operating areas and its consequent preparation throughout the production chain.

  • Improvement in active management of production scheduling.


Floor Control


  • Reduction in production costs.

  • Increase in productivity and efficiency.

  • Reduction of waste.

  • Increase in compliance with the production schedule.

  • Reduction in overtime.

  • Better communication between areas.

Maintenance


  • Reduction of unscheduled machinery downtime.

  • Greater availability of equipment and replacement parts.

  • Increase in the distribution of time invested inPreventive Maintenance.

  • Improvement in internal service level.


Quality


  • Reduction of reprocesses.

  • Reduction of rejections.

Our customers

Limberly
Parmalat
Enaex
Lacoste
devanlay
Owens illions
heineken
benckiser

“Some of the results achieved were: a 20% increase in the plant’s productivity, a 59% reduction in the percentage of repairs and a 51% improvement in quality through the efficient control of each of the production areas: Cutting, Sewing, Inspection, Finishing and Embroidery.”

- Badis Kouidrat, General Manager, Devanlay Lacoste, (Perú) ROI 3.5 a 1