- Improvement of production processes
- Improvement of internal logistics and warehousing
- Improvement of operational planning
- Improvement of quality management systems
- Building leaders and improving the performance of managers
- Building quality and productivity awareness
BRANŻA LOTNICZA
MANUFACTURE OF AIRCRAFT AND AIRCRAFT PARTS:
ACTION OBJECTIVE
- Organisation of workstations and implementation of 5S in key production areas.
- Improvement of the production system.
- Improvement of internal logistics.
- Preparation of an internal expert and implementation group.
BENEFITS ACHIEVED
- Reduction in material flow by 70% of the time.
- Reduction in labour intensity by 25%.
- Reduction in inventory by 50%.
LIGHTING INDUSTRY
MANUFACTURE OF LAMPS AND LUMINAIRES:
ACTION OBJECTIVE
- Improvement of work organisation including organisation of workstations.
- Improvement of the production system.
- Implementation of internal logistics.
BENEFITS ACHIEVED
- Reduction in material flow time by 70%.
- Reduction in labour intensity by 30%.
- Reduction in inventory by 70% including inter-operational storage.
AUTOMOTIVE SECTOR
PRODUCTION OF SHOCK ABSORBERS:
ACTION OBJECTIVE
- To improve work organisation and cleanliness on the production floor by implementing 5S.
- Reduction in labour intensity.
BENEFITS ACHIEVED
- Improved quality of manufactured products, shortened lead times of orders improved ergonomics at workstations.
- Improved employee perception of the company.
PRODUCTION OF RUBBER COMPONENTS:
ACTION OBJECTIVE
- To improve work organisation and cleanliness on the production floor by implementing 5S.
BENEFITS ACHIEVED
- Improved quality of manufactured products, reducing lead times by approximately 10%.
- Reduction of final inspection costs by 25%.
- Improved employee perception of the company through improved ergonomics at the workstations.
ENGINE PRODUCTION. DEPARTMENT - PISTON ARMING:
ACTION OBJECTIVE
- Optimal arrangement of equipment and auxiliary tools at workstations.
- Minimise labour intensity in the piston arming department.
BENEFITS ACHIEVED
- Reduction in labour intensity at the piston arming unit workstations by 70%.
- Elimination of inter-process storage.
ENGINE PRODUCTION. DEPARTMENT - HEAD ASSEMBLY:
ACTION OBJECTIVE
- Reduce the number of parts at the production line by 70%.
- Increase frequency of line maintenance from 2 hours to 30 minutes.
BENEFITS ACHIEVED
- Reduction in the number of parts at the line by 70%.
- Reduction in the labour intensity of the logistics process by 50%.
ENGINE PRODUCTION. DEPARTMENT - SHAFT MACHINING:
ACTION OBJECTIVE
- Reduction in quality errors.
- Speeding up the bottleneck process.
- Reduction of changeover times.
BENEFITS ACHIEVED
- Reduction in quality errors by 50%.
- Speeding up the process by 6%.
- Reduction in set-up time from 180 min to 20 min.
PRODUKCJA SILNIKÓW. WYDZIAŁ - MONTAŻ GŁOWIC:
CEL DZIAŁANIA
- Zmniejszenie ilości części przy linii produkcyjnej o 70%.
- Zwiększenie częstotliwości obsługi linii z 2 godzin do 30 minut.
OSIĄGNIĘTE KORZYŚCI
- Zmniejszenie ilości części przy linii o 70%.
- Zmniejszenie pracochłonności procesu logistycznego o 50%.
PRODUKCJA SILNIKÓW. WYDZIAŁ - OBRÓBKA WAŁÓW:
CEL DZIAŁANIA
- Zmniejszenie ilości błędów jakościowych.
- Przyspieszenie procesu w wąskim gardle.
- Skrócenie czasu przezbrojenia.
OSIĄGNIĘTE KORZYŚCI
- Zmniejszenie ilości błędów jakościowych o 50%.
- Przyspieszenie procesu o 6%.
- Redukcja czasu przezbrojeniaze 180 min do 20 min.
KNITTING INDUSTRY
RIBBON PRODUCTION:
ACTION OBJECTIVE
- Optimisation of work activities.
- Reduction of changeover times.
BENEFITS ACHIEVED
- Reduction in changeover times by 30%.
- Reduction in production costs by 25%.
PHARMACEUTICAL SECTOR
MANUFACTURE OF MEDICINAL PRODUCTS AND MEDICAL DEVICES:
ACTION OBJECTIVE
- To optimise the work of Quality Control and laboratory staff.
BENEFITS ACHIEVED
- Increase in the use of measuring equipment by 30%.
WHITE GOODS INDUSTRY
OVEN PRODUCTION. ASSEMBLY LINES:
ACTION OBJECTIVE
- To optimise the way parts are supplied to the oven assembly line in the white goods industry in order to eliminate line downtime due to parts shortages.
BENEFITS ACHIEVED
- Implementation of line service at 2-hour intervals.
- Elimination of line downtime due to failure to deliver parts on time by 98%.
PRODUCTION OF HOTPLATES. ASSEMBLY LINES:
ACTION OBJECTIVE
- To optimise the way parts are delivered to the oven assembly line in the white goods industry in order to eliminate line downtime due to lack of parts.
BENEFITS ACHIEVED
- Reduction of assembly errors by 90%.
ANIMAL NUTRITION INDUSTRY
OBJECTIVE
- To examine employee relations and the level of management in terms of establishing a company strategy and implementing a philosophy of continuous improvement based on TQM (Total Quality Management).
BENEFITS ACHIEVED
- Implementation of the TQM approach.
- Establish the strategic goals of the organisation in the context of corporate requirements and translate them into specific areas of the company, increasing their efficient functioning.
- Reducing management involvement in operational activities by 90%.
- Increased effectiveness of organisational problem solving by 80%.
FOOD INDUSTRY
MANUFACTURE AND SALE OF FURNITURE AND HOME FURNISHINGS:
ACTION OBJECTIVE
- To obtain trained experts at Lean Six Sigma Green Belt level to improve internal projects for quality improvement and process cost reduction within the organisation and within sub-supplier development.
BENEFITS ACHIEVED
- Developing a cadre capable of leading improvement projects independently.
- Launch of pilot cost-reducing improvement projects by participants.
- Quality improvement and cost reduction through the launch of Lean Six Sigma projects in the organisation.
- More effective work of teams implementing improvement projects using computational and statistical methods.
PACKAGING INDUSTRY
MANUFACTURE OF PLASTIC AND PAPER PACKAGING:
ACTION OBJECTIVE
- To use Statistical Process Control (SPC) tools to monitor and evaluate the performance of production processes on an ongoing (on-line) basis. Intended result - process optimisation, reduction of defects.
BENEFITS ACHIEVED
- A functioning process monitoring system based on developed tools for obtaining process information and the client's IT resources.
- Knowledge and ability to independently configure the programme, create control plans and inspection plans. Ability to analyse data
PRODUCTION OF GLASS PACKAGING - JARS, BOTTLES:
ACTION OBJECTIVE
- To implement Layered Process Auditing - LPA.
BENEFITS ACHIEVED
- Developed in-house system for the company to monitor process status and improve communication in production areas.
- In order to effectively verify work rules and applicable work standards at individual workplaces, thus giving the organisation the possibility to effectively manage human resources.
- Standardised work described and implemented.
- Structured stratified audits and established rules for reporting and visualising audit results for the pilot area.
- Participants know how to conduct stratified audits in the pilot area and can apply them to other areas.
CONSTRUCTION INDUSTRY
MANUFACTURE OF TOOLS FOR ASSEMBLY WORK:
ACTION OBJECTIVE
- Readiness of the company to pass customer quality audits at any time by meeting the conditions of comprehensive quality management.
BENEFITS ACHIEVED
- Fulfilment of quality and organisational expectations of major customers through fulfilment of process management requirements according to VDA 6.3
- Company prepared for customer audits.
- Company prepared for certification to the requirements of the new ISO 9001:2015 standard for quality assurance and process management.
- Increased credibility in the eyes of customers.
- Employees aware of the impact of their own work on other processes, on the customer and on company performance.
- A system that is ready to be self-managed in subsequent periods by company employees.
PRODUCTION OF PREMIUM DOOR AND WINDOW JOINERY:
ACTION OBJECTIVE
- To prepare the FMEA process as transparent and understandable for the company's employees.
BENEFITS ACHIEVED
- Preparation to independently conduct FMEA risk analysis for new and ongoing projects.
- Products have a much lower risk of errors.
- Reduced repair and service costs.
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RAIL INDUSTRY
PRODUCTION OF COMPONENTS FOR RAIL VEHICLES:
ACTION OBJECTIVE
- To ensure effective supply management in production and quality and purchasing processes in order to increase the efficiency of its processes.
BENEFITS ACHIEVED
- Construction of good input from supplier requirements and rules of thumb for the delivery tracking process in the production process and output from the production process, which enables effective feedback to the supplier and improves the supplier management process.
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AUTOMOTIVE SECTOR
MANUFACTURE OF PRECISION STAMPED METAL COMPONENTS:
ACTION OBJECTIVE
- Adaptation to the implementation of IATF 16949.
- Implement process approach and new standards in conjunction with corporate requirements.
BENEFITS ACHIEVED
- Meeting customer expectations in preparation for IATF 16949 system certification.
- Optimising business processes while minimising business costs (e.g. reducing complaints) by using the new mechanisms proposed in the revised version of ISO 9001:2015 and the IATF 16949 standard.
PRODUCTION OF NON-WOVEN FABRICS AND CAR MATS:
ACTION OBJECTIVE
- To align the organisation with the requirements of the new ISO 9001:2015 standard and the IATF 16949:2016 standard.
BENEFITS ACHIEVED
- Meeting customer expectations in terms of preparation for IATF 16949:2016 system certification
- Increased customer confidence and increased order volumes.
- Optimising business processes while minimising business costs.
- Reducing the number of complaints by using the new mechanisms proposed in the revised version of ISO 9001:2015 and the IATF 16949:2016 standard.
- Increase the efficiency and effectiveness of the organisation's employees by raising their awareness during the training provided.
PRODUCTION OF WIDE-AREA FERRITE COMPONENTS AND CORES:
ACTION OBJECTIVE
- To adapt to the implementation of IATF 16949:2016.
BENEFITS ACHIEVED
- Meeting customer expectations in terms of meeting ISO 9001:2015 requirements and preparing for IATF 16 949:2016 system certification.
- Optimisation of business processes while minimising the costs of the IATF 16 949 standard and ISO 9001:2015 business.
- Increase the efficiency and effectiveness of the organisation's employees by raising their awareness of the quality expected by the customer.
MANUFACTURE OF FUEL HOSES AND AIR CONDITIONING HOSES:
ACTION OBJECTIVE
- To prepare employees to act as coordinators for the implementation of the Six Sigma methodology. to create from scratch a team able to solve, using the Six Sigma methodology, complex process and quality problems.
BENEFITS ACHIEVED
- 10 improvement projects completed with detailed change proposals accepted by top management.
- Trained Six Sigma coordinators with the competence to independently lead improvement projects at Green Belt level.
- Prepared managers to act as sponsors of improvement projects and able to support project managers.
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PRODUKCJA KOMPONENTÓW I RDZENI FERRYTOWYCH SZEROKIEGO ZASTOSOWANIA:
CEL DZIAŁANIA
- Przystosowanie do wdrożenia IATF 16949:2016.
OSIĄGNIĘTE KORZYŚCI
- Spełnienie oczekiwań klientów w zakresie spełnienia wymagań ISO 9001:2015 oraz przygotowania do certyfikacji systemu IATF 16 949:2016.
- Zoptymalizowanie procesów biznesowych przy minimalizacji kosztów prowadzonej działalności standardu IATF 16 949 oraz ISO 9001:2015.
- Podniesienie efektywności i skuteczności pracy pracowników organizacji, poprzez podniesienie poziomu ich świadomości dotyczącej jakości oczekiwanej przez Klienta.
PRODUKCJA PRZEWODÓW PALIWOWYCH I PRZEWODÓW KLIMATYZACJI:
CEL DZIAŁANIA
- Przygotowanie pracowników do roli koordynatorów wdrożenia metodologii Six Sigma. stworzenie od podstaw zespołu będącego w stanie rozwiązywać, przy wykorzystaniu metodologii Six Sigma, złożone problemy procesowe i jakościowe.
OSIĄGNIĘTE KORZYŚCI
- 10 projektów doskonalących zakończonych szczegółowymi propozycjami zmian zaakceptowanymi przez najwyższe kierownictwo.
- Przeszkoleni koordynatorzy Six Sigma mający kompetencje do samodzielnego prowadzenia projektów doskonalących na poziomie Green Belt.
- Przygotowani menedżerowie do roli sponsorów projektów doskonalących i potrafiący wspierać menedżerów projektów.
METAL INDUSTRY
MANUFACTURE OF STAINLESS STEEL EQUIPMENT FOR A WIDE RANGE OF INDUSTRIES INCLUDING FOOD AND AUTOMOTIVE:
ACTION OBJECTIVE
- To prepare staff to conduct and prepare VDA 6.3 audits.
BENEFITS ACHIEVED
- To familiarise with the guidelines of VDA 6.3 standard for auditing the production process in the automotive industry. Systematising knowledge of the requirements of VDA 6.3:2016.
- Exchange of experience with a practitioner trainer on the specific requirements of VDA 6.3:2016.
CONTRACT MANUFACTURING OF METAL COMPONENTS AND FINISHED PRODUCTS FOR THE ENERGY, ELECTRICAL, MEDICAL AND OTHER INDUSTRIES:
ACTION OBJECTIVE
- Increase productivity.
- Reduce major waste and mismanagement.
- Increase employees' quality and productivity awareness.
- Faster introduction of new employees to jobs.
BENEFITS ACHIEVED
- Prepared induction training for new employees in Health & Safety, Quality, Environment.
- Examined 8 core production processes and prepared development and improvement activities.
- Implemented rapid improvement actions to reduce lead times by 20 - 25%.
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FOOD INDUSTRY
PRODUCTION OF NUTRIENTS:
ACTION OBJECTIVE
To prepare employees for their roles in the organisation within:
- Leadership Academy
- Coach Academy
- Manager Academy
BENEFITS ACHIEVED
- Increased leadership and skills in the use of management tools at all levels of the organisation.
- Prepare internal trainers to deliver personal skills training to company site employees.
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PLASTICS INDUSTRY
PRODUCTION OF SPECIALISED FOOTWEAR FOR THE MEDICAL INDUSTRY AND SPECIAL APPLICATIONS:
ACTION OBJECTIVE
- Implementation of Lean Manufacturing tools to improve production and logistics processes.
BENEFITS ACHIEVED
- Increased productivity, improved flow in two production units - the plastics paint shop and the injection moulding and footwear production area.
- Increased paint shop productivity by 40%
- Increased productivity in the injection moulding area by 15%.
CHEMICAL INDUSTRY
OBJECTIVE OF THE ACTIVITY
- To acquire the skills to implement innovative organisational changes in administrative and production processes.
BENEFITS ACHIEVED
- To develop innovative process changes.
- To describe, review and propose an improved future state of processes.
- Presentation to the Board of Directors of proposals for improvements to administrative and production processes.