lean production and simulation


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Delfoi Lean is a project model that enables radical improvements in productivity. With existing resources, production volumes can be increased e.g. as much as 50% or lead-time shortened by 70% or more.

By using Delfoi Lean development methods and simulation, the impact of different production system changes be calculated with simulation before implementation with great accuracy. Typically, when Delfoi Lean service concept and simulation is used, the customer can validate the effects by a 95% certainty, i.e. actual effect measured in real-world versus simulated effect in virtual world. Delfoi has vast experience of productivity improvement projects since 1990. Our ability to improve our customers’ production is based on our previous experiences and solid background in simulation. Our experience during the past twenty-eight years covers over a thousand successful customer projects.

Valio Joensuu.jpg Figure. Valio, simulation model for the Joensuu plant

Delfoi Lean is a project model that enables radical improvements in productivity. With existing resources, production volumes can be increased e.g. as much as 50% or lead-time shortened by 70% or more.

By using Delfoi Lean development methods and simulation, the impact of different production system changes be calculated with simulation before implementation with great accuracy. Typically, when Delfoi Lean service concept and simulation is used, the customer can validate the effects by a 95% certainty, i.e. actual effect measured in real-world versus simulated effect in virtual world. Delfoi has vast experience of productivity improvement projects since 1990. Our ability to improve our customers’ production is based on our previous experiences and solid background in simulation. Our experience during the past twenty-eight years covers over a thousand successful customer projects.

ACCURATE SIMULATION

The results realized after Delfoi Lean Factory projects are usually very close to the results predicted in simulation. On average, realized results match with the simulated results on more than 95% accuracy level.

DESCRIPTION OF SERVICE MODEL

STEP 1: VALUE / Specification of value creation and need for development

Delfoi analyses thoroughly the current state of the most important processes and identifies development areas. Together with the customer, target-levels are set. This analysis also works as a baseline for the follow-up of the impacts after changes are made.

STEP 2: VALUE CHAIN / Specification of target state value chain

For the selected value chains and processes, a target state is specified. How the value chain or it’s processes should function ideal state, is defined and analyzed. This means that all the waste and restrictions related to current state are identified and targets are set, how to eliminate waste in the processes. The targeted ideal state should be hard to achieve but not impossible. Also milestones on the way to the target state can be identified.

STEP 3: SOLUTION / Design, simulation and recommendations

The target state approved by management and different parties needs further planning and this is the phase where one or several concrete alternatives are specified in detail. The new processes and layouts are then tested with a discrete-event- simulation model, before they are approved and recommended for implementation. Verification through simulation makes it possible to ensure, that the development actions will actually lead to the desired impact on lead-times, capacity and productivity. Simulation also improves cooperation during the development and planning phase. With the help of 3D-simulation model, it is easier to show the concrete changes and effects in the production system in advance to different interest groups and this manage the risk of change resistance. It is easier to accept changes, when they are presented in an easy-to-understand and realistic way before implementation starts. 

STEP 4: IMPLEMENTATION / Implementation and follow-up

In the implementation stage of the Delfoi Lean project model, the actions and possible investments required to achieve the target state are taken into practice together with the personnel. This way it is also possible, that personnel is engaged as part of the change proves and they are given the required tools to continue development independently after the project.

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