Implementing Lean Tools

We offer implementation of the whole range of tools from the so-called Lean Toolbox. We carry out original, nationwide projects of implementing the 5S, SMED and TPM method within the proven, standardized programs of the 5S Champions League, SMED Challenger and TPM Champion.

Lean Tools

LUQAM carries out projects of implementation of particular Lean Management tools, including:

5STPM
Flow AnalysisHeijunka
Hoshin SMED
KanbanValue Stream Mapping VSM
Standardized workKaizen
3PJidoka
Poka-yokeJust in Time
OEEZarządzanie wizualne
One piece flowSystem Pull

 

In the case of tools such as the 5S method, SMED (rapid change-over of machines and devices) and TPM (complex productive maintenance), we offer our customers participation in LUQAM’s optimization products, which are:

5S Champions League, SMED Challenger and TPM Champion.

 

Individual types of projects listed in LUQAM’s offer are conducted in a standardized mode. This means that a given product has a set of standards that facilitate its efficient management and that its purpose is known beforehand. The way of conducting these projects is determined by many years of practice and the standard based on it, which combined with an individual approach allows to maximize the added value for a given organization.

Free dedicated trainings

Each of the companies participating in any of the above mentioned projects, apart from the benefits resulting from its specificity, receives an opportunity for free participation in LUQAM dedicated training courses (training in Lean, Six Sigma tools and operational management).

Champions
League 5S

The 5S method is a tool for continuous improvement and a basic pillar of Lean Manufacturing.

The aim of applying 5S principles in an organization is primarily to create a safe and ergonomic workplace.

THE 5S CHAMPIONS LEAGUE is a group of companies that focus on 5S development through independent audits or workshops conducted by LUQAM experts. The main goal of the program is to identify areas with potential for improvement and to build a foundation for optimization according to the concept of Lean Management. The 5S Champions League enables the implementation of the 5S method at the highest level, and most importantly – permanently.

Participants of the 5S Champions League are companies from various industries, both manufacturing and service, interested in maintaining and developing work safety and ergonomics. The innovative and complete strategy created by us serves the continuous improvement of 5S level in all types of organizations.

We were the first and only company in Poland to create a complete strategy for the improvement of level 6S in all types of organizations.

10 key benefits of
the 5S method
implementation
in the organization

I. Increasing worker safety by improving health and safety and work ergonomics.

II. Increasing productivity by eliminating losses.

III. Reduction of production costs through standardization, elimination of production losses and unnecessary things and better management of the machine park.

IV. Improvement of product quality thanks to observing and maintaining the principles of technology and work standardization.

V. Reduction of waste through better use of materials.

VI. Raising the brand and reputation of the company through cleanliness, neatness and transparency of production departments, warehouses, offices and factory surroundings.

VII. Increasing discipline and motivation of employees by assigning responsibility and bringing the KAIZEN spirit to the organization.

VIII. Standardization of processes and management.

IX. Use of hidden reserves, especially with regard to employees’ working time.

X. Prepare the basis for the implementation of other Lean Manufacturing tools and strive for organizational excellence.

The most frequently cited benefits of participating in the LM5S by our customers:

There is no need to reactivate 5S after a few or more months.

With the 5S Championship League, the commitment and motivation of the employees is maintained.”

Based on the experience
of our customers, we have
created three program variants:

5S Champions League

The standard program formula for companies with implemented 5S includes:

Pre-audit and individual action plan tailored to the specificity of the organization,
audits, on the basis of which the assessment is calculated and the action plan is updated,
access to the online platform www.ligamistrzow5s.pl, where the results of subsequent audits, reports, place in the general ranking, etc. are recorded on an ongoing basis,
• a quarterly pot of specialized trainings,
• the possibility of mutual visits to companies,
gadgets starter package – 5S posters, scoreboards, red cards,
e-learning course 5S Method,
free subscription to the Optimizer Review magazine,
certificate and additional awards for best results.

5S Youth Champions League 

Variant for companies that want to professionally implement the 5S method in a given area

Young 5S Champions League is a solution created for companies whose goal is to implement 5S system in their organization.

The formula of the program allows to train employees in the 5S Method and to conduct few days of workshops (calibration, implementation or standardization workshop). The company receives a package of 5S forms and a plan of further actions. After the training and workshops, the company starts an evaluation audit and can continue workshops in other areas or enter the 5S Standard Champions League.

5S Champions League Premium

Variant for companies that want to accelerate the 5S development progress

The Premium formula is a combination of audits and workshops, thanks to which the company makes more frequent use of consultants’ visits.

SMED Challenger

What is SMED?

SMED is unique compared to other Lean Manufacturing tools. Why? Because some of the tools do not allow you to easily see the savings generated.

In contrast, SMED allows you to directly indicate the time savings and therefore increases flexibility and efficiency of production. It is a set of techniques allowing to shorten the time of changeover, which in a very simple way increases productivity.

Program SMED Challenger

What is it?

SMED Challenger is a product that helps to understand the SMED method, developed by TOYOTA.

The most important goal of SMED is to show the employees that ” it is possible” to significantly shorten the time of changeover and make it predictable. And if ” it is possible”, why not do it all over the company?

The program:

• The project plan is scheduled for 12 months

11 days of workshops and consultations

• From 1 to 4 different machines covered by a system implementation

Additional SMED benefits

With us, employee development is possible!

Especially for the participants of our program, we have prepared a package of training courses for which 2 people can be registered in a quarter at no additional cost.

Przykładowy kwartalny harmonogram szkoleń:

Take up the
SMED challenge

We risk because there is no certainty that the goal will always be achieved

…a but there’s only one risk on your side – time spent. On the basis of the workshop results presented by LUQAM showing possible effects – you accept the launch of a project with us, during which we will help to implement SMED in the whole company.

.

PRINCIPLES OF THE CHALLENGE

• LUQAM selects the machine and the type of changeover.
• LUQAM offers a challenge objective, e.g. to reduce the changeover time on the machine by 25%/15 minutes.
• THE CLIENT accepts the challenge.
• LUQAM is committed to carry out a two-day SMED workshop at its own expense if the goal of the challenge is not achieved.
• THE CLIENT agrees to continue the joint activities if the objective of the SMED Challenger project is achieved.

How does the
project look like?

The project plan is scheduled for a minimum of 12 months with the possibility of extension. It includes 11 days of workshops and consultations. Depending on the customer’s needs, 1, 2, 3 or 4 machines may be included in the system implementation.

In the SMED Challenger programme, success is primarily about understanding the SMED methodology, bringing the production department together with the support departments in a common system operation to improve the machine changeover process.

They all follow the same path, are one group and, as a result, they follow the instructions and carry out the changeover process safely, repeatably and quickly. As a result, the SMED Challenger allows you to develop an optimal SMED model.

TPM

Total Productive Maintenance is a Lean Management tool that is worth developing within the Lean Manufacturing approach. It will prove its worthwhile in production facilities.

TPM Champion is an annual project focused on the effective and tailor-made implementation and improvement of TPM. The programme is addressed to companies that want to maximise the availability of critical equipment and eliminate failures, shortages and accidents at work.

Basic benefits from participation

• Individually designed TPM development system and professional, annual support in its implementation.

• Exhaustive number of trainings, workshops and audits, which systematically broaden theoretical and practical knowledge of employees, which translates into improvement of TPM level.

• Trained and informed managers in the production and maintenance departments (SUR).

• Employees who actively support the prevention, detecting machine failures at an early stage.

• Reduced number of failures and micro downtimes, which increases the predictability of production and increases the efficiency of the machine park.

• Reduction of production costs.

• A package of training courses for which 2 people can be registered in a quarter without additional costs. The total savings from this package is as much as 1760 PLN per quarter.

Programme
formula

Implementation of TPM in a company is a long-term process, which should be properly prepared and consciously guided. The most important thing is a gradual implementation of the plan. Employees must get used to their new responsibilities, the work of coordinators and the schedule of meetings requires additional time. Therefore, for everything to work, the process must be carried out in stages.

 

The program is based on a proven standard of implementation carried out step by step, systemically, without chaos.

TPM CHAMPION focuses on the most important activities:
Autonomous Maintenance System (AUR),
• building operators’ awareness,
Problem Solving,
training,
Planning of Maintenance and Repair (PUR).
TPM CHAMPION variants:
The possibility of choosing the TPM Champion variant,
the support of a consultant at every stage,
• formal audits,
• the final audit ending each of the variants,
regular audits for interested people,
precise customer guidelines for each variant

Lean Tools

LUQAM carries out projects of implementation of particular Lean Management tools, including:

5STPM
Flow AnalysisHeijunka
Hoshin SMED
KanbanValue Stream Mapping VSM
Standardized workKaizen
3PJidoka
Poka-yokeJust in Time
OEEZarządzanie wizualne
One piece flowSystem Pull

 

In the case of tools such as the 5S method, SMED (rapid change-over of machines and devices) and TPM (complex productive maintenance), we offer our customers participation in LUQAM’s optimization products, which are:

5S Champions League, SMED Challenger and TPM Champion.

 

Individual types of projects listed in LUQAM’s offer are conducted in a standardized mode. This means that a given product has a set of standards that facilitate its efficient management and that its purpose is known beforehand. The way of conducting these projects is determined by many years of practice and the standard based on it, which combined with an individual approach allows to maximize the added value for a given organization.

Free dedicated trainings

Each of the companies participating in any of the above mentioned projects, apart from the benefits resulting from its specificity, receives an opportunity for free participation in LUQAM dedicated training courses (training in Lean, Six Sigma tools and operational management).

Champions
League 5S

The 5S method is a tool for continuous improvement and a basic pillar of Lean Manufacturing.

The aim of applying 5S principles in an organization is primarily to create a safe and ergonomic workplace.

THE 5S CHAMPIONS LEAGUE is a group of companies that focus on 5S development through independent audits or workshops conducted by LUQAM experts. The main goal of the program is to identify areas with potential for improvement and to build a foundation for optimization according to the concept of Lean Management. The 5S Champions League enables the implementation of the 5S method at the highest level, and most importantly – permanently.

Participants of the 5S Champions League are companies from various industries, both manufacturing and service, interested in maintaining and developing work safety and ergonomics. The innovative and complete strategy created by us serves the continuous improvement of 5S level in all types of organizations.

We were the first and only company in Poland to create a complete strategy for the improvement of level 6S in all types of organizations.

10 key benefits of
the 5S method
implementation
in the organization

I. Increasing worker safety by improving health and safety and work ergonomics.

II. Increasing productivity by eliminating losses.

III. Reduction of production costs through standardization, elimination of production losses and unnecessary things and better management of the machine park.

IV. Improvement of product quality thanks to observing and maintaining the principles of technology and work standardization.

V. Reduction of waste through better use of materials.

VI. Raising the brand and reputation of the company through cleanliness, neatness and transparency of production departments, warehouses, offices and factory surroundings.

VII. Increasing discipline and motivation of employees by assigning responsibility and bringing the KAIZEN spirit to the organization.

VIII. Standardization of processes and management.

IX. Use of hidden reserves, especially with regard to employees’ working time.

X. Prepare the basis for the implementation of other Lean Manufacturing tools and strive for organizational excellence.

The most frequently cited benefits of participating in the LM5S by our customers:

There is no need to reactivate 5S after a few or more months.

With the 5S Championship League, the commitment and motivation of the employees is maintained.”

Based on the experience
of our customers, we have
created three program variants:

5S Champions League

The standard program formula for companies with implemented 5S includes:

Pre-audit and individual action plan tailored to the specificity of the organization,
audits, on the basis of which the assessment is calculated and the action plan is updated,
access to the online platform www.ligamistrzow5s.pl, where the results of subsequent audits, reports, place in the general ranking, etc. are recorded on an ongoing basis,
• a quarterly pot of specialized trainings,
• the possibility of mutual visits to companies,
gadgets starter package – 5S posters, scoreboards, red cards,
e-learning course 5S Method,
free subscription to the Optimizer Review magazine,
certificate and additional awards for best results.

5S Youth Champions League 

Variant for companies that want to professionally implement the 5S method in a given area

Young 5S Champions League is a solution created for companies whose goal is to implement 5S system in their organization.

The formula of the program allows to train employees in the 5S Method and to conduct few days of workshops (calibration, implementation or standardization workshop). The company receives a package of 5S forms and a plan of further actions. After the training and workshops, the company starts an evaluation audit and can continue workshops in other areas or enter the 5S Standard Champions League.

5S Champions League Premium

Variant for companies that want to accelerate the 5S development progress

The Premium formula is a combination of audits and workshops, thanks to which the company makes more frequent use of consultants’ visits.

SMED Challenger

What is SMED?

SMED is unique compared to other Lean Manufacturing tools. Why? Because some of the tools do not allow you to easily see the savings generated.

In contrast, SMED allows you to directly indicate the time savings and therefore increases flexibility and efficiency of production. It is a set of techniques allowing to shorten the time of changeover, which in a very simple way increases productivity.

Program SMED Challenger

What is it?

SMED Challenger is a product that helps to understand the SMED method, developed by TOYOTA.

The most important goal of SMED is to show the employees that ” it is possible” to significantly shorten the time of changeover and make it predictable. And if ” it is possible”, why not do it all over the company?

The program:

• The project plan is scheduled for 12 months

11 days of workshops and consultations

• From 1 to 4 different machines covered by a system implementation

Additional SMED benefits

With us, employee development is possible!

Especially for the participants of our program, we have prepared a package of training courses for which 2 people can be registered in a quarter at no additional cost.

Przykładowy kwartalny harmonogram szkoleń:

Take up the
SMED challenge

We risk because there is no certainty that the goal will always be achieved

…a but there’s only one risk on your side – time spent. On the basis of the workshop results presented by LUQAM showing possible effects – you accept the launch of a project with us, during which we will help to implement SMED in the whole company.

.

PRINCIPLES OF THE CHALLENGE

• LUQAM selects the machine and the type of changeover.
• LUQAM offers a challenge objective, e.g. to reduce the changeover time on the machine by 25%/15 minutes.
• THE CLIENT accepts the challenge.
• LUQAM is committed to carry out a two-day SMED workshop at its own expense if the goal of the challenge is not achieved.
• THE CLIENT agrees to continue the joint activities if the objective of the SMED Challenger project is achieved.

How does the
project look like?

The project plan is scheduled for a minimum of 12 months with the possibility of extension. It includes 11 days of workshops and consultations. Depending on the customer’s needs, 1, 2, 3 or 4 machines may be included in the system implementation.

In the SMED Challenger programme, success is primarily about understanding the SMED methodology, bringing the production department together with the support departments in a common system operation to improve the machine changeover process.

They all follow the same path, are one group and, as a result, they follow the instructions and carry out the changeover process safely, repeatably and quickly. As a result, the SMED Challenger allows you to develop an optimal SMED model.

TPM

Total Productive Maintenance is a Lean Management tool that is worth developing within the Lean Manufacturing approach. It will prove its worthwhile in production facilities.

TPM Champion is an annual project focused on the effective and tailor-made implementation and improvement of TPM. The programme is addressed to companies that want to maximise the availability of critical equipment and eliminate failures, shortages and accidents at work.

Basic benefits from participation

• Individually designed TPM development system and professional, annual support in its implementation.

• Exhaustive number of trainings, workshops and audits, which systematically broaden theoretical and practical knowledge of employees, which translates into improvement of TPM level.

• Trained and informed managers in the production and maintenance departments (SUR).

• Employees who actively support the prevention, detecting machine failures at an early stage.

• Reduced number of failures and micro downtimes, which increases the predictability of production and increases the efficiency of the machine park.

• Reduction of production costs.

• A package of training courses for which 2 people can be registered in a quarter without additional costs. The total savings from this package is as much as 1760 PLN per quarter.

Programme
formula

Implementation of TPM in a company is a long-term process, which should be properly prepared and consciously guided. The most important thing is a gradual implementation of the plan. Employees must get used to their new responsibilities, the work of coordinators and the schedule of meetings requires additional time. Therefore, for everything to work, the process must be carried out in stages.

 

The program is based on a proven standard of implementation carried out step by step, systemically, without chaos.

TPM CHAMPION focuses on the most important activities:
Autonomous Maintenance System (AUR),
• building operators’ awareness,
Problem Solving,
training,
Planning of Maintenance and Repair (PUR).
TPM CHAMPION variants:
The possibility of choosing the TPM Champion variant,
the support of a consultant at every stage,
• formal audits,
• the final audit ending each of the variants,
regular audits for interested people,
precise customer guidelines for each variant

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