lean production and simulation
Delfoi Lean is a project model that enables radical improvements in productivity. With no added production resources, production increases or lead-time shortening by as much as 70%, and typically more than 50%, have been attained.
By deploying a Delfoi Lean productivity project and related simulation, the effectiveness of productivity can be calculated in advance by 95% certainty.
The Delfoi Lean service model is applied to design a company a customised productivity development solution based on a result verified by a 95% certainty through simulation. Delfoi has provided productivity improvement projects to industry since 1990. Our ability to improve our customers’ productivity is based on our previous experiences and solid background in simulation accumulated over the past twenty years and in hundreds of customer projects.
Figure. Valio, simulation model for the Joensuu plant
We improve the efficiency of lean programmes applied in companies. What we add to a traditional, continuous and yet cautious lean development programme is our simulation competence. Simulation allows us to also look into improvement alternatives which companies would otherwise not implement due to excessive risks related to expenses or a possible failure. When the effectiveness of intended measures can be seen in advance before initiating the actual implementation, it is possible to also launch development projects involving high risks but also superior benefits.
The Delfoi Lean project model is based on a host of successful projects. Regardless of the initial situation or the size of the company, project results have been remarkable. Our customers include
ABB (several plants), Cargotec, Hollming Works, Ponsse, Technip, Procter & Gamble, Ruukki, Rocla, Metso Paper, NOKIA, Valio, Volvo Trucks (cabin plant in Umeå)
The results realised in Delfoi Lean Factory projects have been highly equivalent to the results predicted in simulation. Results realised match the simulated results with more than 95% accuracy.
Description of service model
VALUE / Specification of value creation and need for development
Delfoi analyses the current state of the most important value chains and selects development targets. This analysis also works as a baseline for the follow-up of the impacts of the changes.
VALUE CHAIN / Specification of value chain
For the value chain, a target state is specified that describes how the value chain should operate without restrictions from the current work practices or premises.
SOLUTION / Design and simulation
The target state approved by the corporate management is put into concrete terms and designed to the detail. The new processes and layouts are tested with an event-based simulation model before they are implemented in practice. Verification through simulation makes it possible to ensure that the development measures bear the desired impact on lead-times, capacity and productivity. For example, measures aiming at a 50% reduction in lead-time have been verified in advance and even actions involving risks and higher benefits can be implemented. Simulation also improves cooperation. A simulation model can be used to indicate the impacts of changes in advance to different production interest groups and to prevent the rise of forces undermining the willingness to change when taking incomplete plans to practice.
IMPLEMENTATION / Implementation and follow-up
At the implementation stage of the Delfoi Lean project model, the measures and changes required to achieve the target state are taken into practice together with the personnel. This way, the personnel is engaged as part of the change and they are given the required tools to continue development independently.