Considi's experience and know-how make it possible to export TPS concepts (historically born in Toyota's batch production) within companies that work by order, through a time-tested transformation model that applies the organisation of ETO companies - engineering to order - with a lean approach. Drivers across all stages of the model include:
- The introduction of Visual Management for workload balancing
- A quantitative approach to remove subjectivity from processes
- Overview to prioritise crossing time
- Creation of cohesive and aligned job development teams
STEP 1: Offer To Order
- Creation of an in-service offer engineering to inside sales
- Adoption of a contribution margin pricing policy from the complexity/volume matrix
- Standardisation of the offers
- Estimation of the generation time of an offer according to type
- Generation of KPIs to monitor the success rate of offers and the number of customer reviews
STEP 2: Order To Manufacturing
- Relocation of production engineering within the Genba
- Creation of a structured archive useful as a starting point for the technical development of the latest revision of the offer while facilitating knowledge reuse
- Standardisation of tools for the drafting of attached documentation
- Estimated technical development time depending on the complexity of the order (Bin System)
- Agile Management of Job Development Teams
- Generation of KPIs to monitor the status and throughput time of orders
STEP 3: Manufacturing to Shipping
- Reorganisation by production flows (mini-factories) with overall OEE
- Grouping of homogeneous processing
- Restructuring of operations in the form of phase and pull programming with standard lead times
- Definition of machine and assembly cycles grouped by component models
- Renegotiation of delivery dates in case of failure to meet lead times
