Efficiency

Efficiency

PeopleFlo’s efficiency system includes a collection of elements that work together to remove non-value-added waste from two value drivers: the product development process and the product production processes.

Production efficiency

One-product-flow production. PeopleFlo’s one-product-flow production system is the leading factor in creating turnkey products lines with superior efficiency. Compared to best practice “lean” methods, one-product-flow production results in an estimated 50% less direct labor and 65% less up-front capital.

Although the one-product-flow production system is built upon “lean” philosophy and tools, it is a fundamentally different and revolutionary way to make products. This proprietary  production system differentiates PeopleFlo’s product lines due to outstanding productivity not only at high volume but also at low volume and small lot sizes. In addition, it enables exceptionally short delivery cycle times.

The one-product-flow production system is capable of producing –

A broad product family, (different sizes and materials)
of industrial products, (high standards of performance, quality and safety)
complete in one cell,
(all steps necessary to produce a complete product)
to order, (based on a wide range of configurations)
from raw material,
(not from work-in-process)
one product at a time,
(with all parts in single-piece-flow)
with flexible scaling.           
(diversified incremental approaches)

Observation tool1. PeopleFlo’s proprietary one-product-flow observation tool enables companies to capture and organize all production work elements and machine cycle times in a way that enables a clear understanding of the current state and makes ongoing improvement possible. It automatically generates standard work instructions for each production activity which is synchronized for the overall system. It also generates standard work combination sheets that make clear the relationship between machines and direct labor associates in time elements as low as two-seconds.

Know-how1. PeopleFlo’s one-product-flow production system is build upon “lean” philosophy and tools. However, it’s a fundamentally different way to produce industrial products. Key elements include:

  • Make-to-order strategy.
  • Systems approach to One-Product-Flow.
  • Associate and machine interdependence standards.
  • Nesting operations and optimizing the sequence.
  • Standardized product and “specials” strategy.
  • Cutting Tool “lock down” standardization.
  • Flexible scaling strategy.
  • Product line design for One-Product-Flow.

Visual controls1. PeopleFlo’s visual control system is used to manage and improve the one-product-flow production system. The visual schedule board highlights deliverables by line item, relative cycle times, and schedule interdependencies. Takt sheets are organized for simultaneous model production and incorporate a work element check-off system.

Plan-For-Every-Part (PFEP) database1. The PFEF database organizes all component information into a simple database. This database can include links to the EzSpec front-end quotation tool and the EzBuild production information tool. In addition, it can be easily incorporated into an existing ERP system. The PFEP database includes complete component descriptions, model associations, cost information, inventory information and raw material information.

Workholding system1. PeopleFlo’s innovative workholding system is designed to eliminate “exposed” changeover time for producing product components and assemblies in a one-product-flow production cell. This workholding system is applied across-the-board for all operations including machining, coating, assembly, test, etc. It is designed for complex components and machines with diverse part geometries, varied part sizes, different part materials and a broad range of features, options and configurations.

Quality assurance technology1. All equipment and related software for in-cycle measurement and process control for every product line component. Equipment integrated into the one-product-flow manufacturing system includes some or all of the following: measurement gauges, go/no go fixtures, CNC machine probe system and the EzRecieve1 incoming material validation tool.

EzSpecquotation toolEzSpec is a front-end software tool that combines model sizing, selection and configuration with the ability to easily generate technical quotations. Quotations include product descriptions, technical specifications, pricing, drawings and delivery lead-time information. EzSpec is designed for simplicity and flexibility. As a result, it can be easily integrated with existing business systems.

EzBuild1. EzBuild is a production software tool that automatically converts EzSpec quotations into the shop floor information necessary to manufacture, assemble and ship. This information includes a pick list, a bill of materials, part drawings and specifications. EzBuild is designed for simplicity and flexibility. As a result, it can be easy integrated with existing business systems.

Product development efficiency

Time to market. PeopleFlo’s turnkey product lines get to market faster through a highly efficient product development process. PeopleFlo’s product development process differs from a traditional stage gate model because it is a more flexible, holistic process. Most importantly, it is built around a powerful product development mapping tool. PeopleFlo’s product development mapping tool provides an essential visibility and a common understanding necessary for efficient management of complex information flows that are highly iterative, deeply interdependent and touch a large diverse group of technical specialists. Without this clear visibility and holistic understanding, the most valuable time-to-market efficiencies gains are impossible.

Appendix quote pic on top

PeopleFlo featured in the book: The Toyota Product Development System

The appendix, entitled Applying Value Stream Mapping to a Product Development Process: The PeopleFlo Manufacturing Inc. Case, highlights PeopleFlo’s innovative use of the value of the value stream mapping tool to manage and improve the product development process.

 The Toyota Product Development System
James Morgan and Jeffrey Liker, 2006