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ATS Sustainable Business Improvement Proposition:
Road to Excellence

ATS developed a generic approach in delivering business improvements to our customers. It is the Lean Six Sigma à la carte menu. This standard approach incorporates lessons learnt and best practices gained from ATS and other implementations. It provides a guideline in implementing a Business Improvement solution and will always be tailored to our customer needs.

ATS Generic Business Improvement approach:
  • Discovery Business Improvement Assessment
  • Improvement Opportunity Definition
  • Improvement Tool(s) Selection
  • Roadmap when and how to realise
  • Realisation via improvement tools & applications
  • Create sustainability of the business improvement




Stage 0: Adopt Lean
To do Consultancy Workshops
  • Define opportunity
  • Establish need
  • Obtain commitment
  • MES awareness
  • Lean audits
  • Six Sigma Quick Scans
  • Program management
MES
  • Introduction
  • Experiences
Lean Manufacturing
  • Introduction
  • Sticky Lean
Six Sigma
  • Basics
  • Best practices
  • Industry focussed
Top leaders commitment
Lean Six Stage 0
Stage 1: Prepare
  Consultancy Training
  • Develop implementation plan
  • Develop a roadmap
  • Train key people
  • Set targets
  • Establish teams
MES
  • MES discovery assesment
Lean Manufacturing
  • Opportunity Assesment
Six Sigma
  • Quick Scans
  • MES awareness
  • Local lean team
    • Waste elimination
    • Variability elimination
    • Inflexibility elimination
    • Flow
    • SMED
    • 5S
    • TPM
Lean roadmap
Lean Six Stage 0
Stage 2: Define Value
  Consultancy  
  • Select initial scope
  • Define value, schedule and target cost
MES
  • Business case
Lean Manufacturing
  • Business case
Six Sigma
  • Quick Scans
 
Lean Six Stage 2
Stage 3: Identify Value Stream
  Consultancy Training
  • Record current state
  • Create product and information flow
  • Collect baseline date
MES
  • Business case
Lean Manufacturing

Six Sigma
  • Quick Scans
Lean Manufacturing
  • Value stream mapping
  • Capacity tunneling
  • Overall Equipment Efectiveness (OEE)
Lean Six Stage 3
Stage 4: Design Production System
  Services Training
  • Develop future state
  • Identify takt time
  • Plan new layout
  • Design visual controls
  • Plan TPM
Lean Manufacturing
  • Practitioner
Six Sigma
  • Black Belt
Lean Manufacturing
  • Cascading KPI Structure
  • Visual Management (Performance boards)
  • Improved Idea Process
  • Standard Operating Procedures
Lean Six Stage 4
Stage 5: Implement Flow
  Products & Services Training
  • Standardize operations
  • Mistake-proof processes
  • Archive process control
  • Implement TPM
  • Implement Self Inspection
  • Eliminate waste
  • Reduce setup times
  • Implement visual controls
Information management
  • MIS
    • ActivPlant
    • Plant2Business
    • Proficy Historian
    • Proficy Real-time Info Portal
  • MES
    • Simatic IT
  • Quality
    • Gauging solutions
    • SPC & SAQ
Lean Manufacturing
  • Practitioner
  • Poka Yoke - Mistake Proofing
  • Auditing
Six Sigma
  • Black Belt
Lean Manufacturing
  • Standardize Operating Procedures
  • Poka Yoke – Mistake Proofing
  • Waste Elimination
  • 5S
  • Auditing
  • Overall Equipment Effectiveness
  • Total Productive Maintenance
  • Failure Mode and Effect Analysis
  • Problem Solving
Six Sigma
  • Yellow Belt
  • Green Belt
  • Champion
  • Statistical Process Control (SPC)
Visual Management
Change Management
Lean Six Stage 5
Stage 6: Implement Pull
  Products & Services Training
  • Select appropriate production system control
  • Strive for one piece flow
  • Balance production flow
  • Reduce inventories
Services
Lean Manufacturing
  • Auditing
  • Capability building
  • Continues improvement infrastructure
Products
Information management
  • MIS
    • ActivPlant
    • Plant2Business
    • Proficy Historian
    • Proficy Real-time Info Portal
  • MES
    • Simatic IT
  • Quality
    • Gauging solutions
    • SPC & SAQ
Lean Manufacturing
  • Kanban implementation
  • Production leveling
Visual Management
Change Management
Lean Six Stage 6
Stages 7 & 8: Strive for Excellence and Sustain Improvements
Products Services
Stage 7 Information management
  • Manufacturing Information Systems
    • ActivPlant
    • Plant2Business
    • Proficy Historian
    • Proficy Real-time Info Portal
  • Manufacturing Execution Systems
    • Siemens Simatic IT
    • Wonderware Archestra
  • Quality
    • Gauging solutions
    • SPC & CAQ
    • In-line and At-line quality systems
    • Laboratory information management systems
Lean Manufacturing
  • Practitioner
  • Auditing
  • Capability building
  • Continues improvement infrastructure
Six Sigma
  • Master Black Belt
  • Project monitoring and selection
Visual management
Change management
  • Quality continuous improvement
  • Team development
  • Institutionalize 5S
  • Evaluate against targets
  • Evaluate progress using lean matrices
Stage 8
  • Quality continuous improvement - SPC
  • Make improvement sustainable
  • Improve process reliability - Six Sigma
Lean Six Stage 7 and 8
Expand to Stage 1: Prepare or start again at Stage 0: Adopt Lean

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