Lean Ofis Presentation

Operational Excellence Solution Provider

Work for your excellenceWork for your excellencewww.leanofis.com

[email protected]

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


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


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


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.


�� 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


1- Lean Transformation

Lean Ofis perform detailed assessment analysis to understand the operationalexcellence maturity and create strategic improvement plan for development.

( Hoshin Plan)



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 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


�� 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


12

3

4

65

30

mm

2- Manufacturing System Design with tubular systemWork for your excellence


2- Manufacturing System Design with tubular system ( samples)

Visual Management Clasical WS Flow Racks


Tailor Made WS Communication Area Supermarket


�� 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


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


3- Lean Innovative Engineering ( Sample Poka & Yoke Machines)Work for your excellence


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,


�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]


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

[email protected]


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

Lean Ofis Presentation

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