We evaluate your operations with Lean audits and KPI analysis, identifying gaps and improvement opportunities aligned with world-class standards.
We evaluate your operations with Lean audits and KPI analysis, identifying gaps and improvement opportunities aligned with world-class standards.
We execute customized solutions using Lean methodologies and PDCA projects, supporting your team with visual control tools for sustainable improvements.
At IDP, our expert team directly implements solutions, ensuring effectiveness, accelerating results, and transferring practical knowledge to client personnel.
We strengthen your team’s capabilities through hands-on coaching and on-site training to foster a continuous improvement culture.
• Waste analysis and identification
• 5S methodology implementation
• Takt time deviation identification
• PDCA projects to reduce waste and variability
• OEE Analysis: Evaluation of equipment operational efficiency
• SMED Methodology: Quick changeovers
• Autonomous Maintenance (AM), CILT routines (Cleaning, Inspection, Lubrication, Tightening)
• Preventive Maintenance (PM): Based on time (TBM), usage, and condition
• Downtime Control & Critical Offenders Identification
• VSM (Value Stream Mapping): Identifying opportunities in material flow
• Master Spare Parts List: Structuring and implementing spare parts inventory
• Preventive Maintenance in SAP: Setup and execution aligned with part availability
• Vertical Start-Up Process: 9-step approach for efficient production ramp-up
• Initial Parameterization & Testing
• Monitoring and Adjustments
• Gradual Ramp-Up
• Regular Production Start
Comprehensive shop floor optimization through practical and measurable Lean methodologies.
5S Implementation
We transform work culture and organization through visual standardization and operational discipline.
Waste Elimination
We apply a systematic approach to identify and eliminate MUDA (waste) in all operational areas.
PDCA Projects
We execute structured continuous improvement cycles focused on reducing variability, costs, and response times.
Data Analysis & RCA
We collect key information to identify root causes and design effective countermeasures.
We maximize asset performance through smart maintenance strategies, downtime reduction, and effective variability control to reach world-class productivity levels.
Overall Equipment Effectiveness (OEE) Improvement
We deeply analyze your equipment’s efficiency using availability, performance, and quality indicators to identify hidden losses and boost real productivity.
Quick Changeovers with SMED
We reduce changeover times using the SMED methodology, increasing operational flexibility and minimizing batch-to-batch interruptions.
Autonomous Maintenance (AM)
We establish CILT routines (Cleaning, Inspection, Lubrication, Tightening) with line operators to prevent recurring failures.
Strategic Prevention (PM)
We develop customized preventive maintenance plans based on time (TBM), usage, or condition to extend asset lifespan.
Downtime and Chronic Offender Management
We implement control and analysis systems to identify failure patterns and recurring issues, ensuring effective corrective actions.
We enhance supply efficiency and spare parts management using Lean tools and digital solutions, strengthening technical and logistics support.
Ideal State
We assess and plan tool provisioning and capacity control.
Value Stream Mapping (VSM)
We identify waste and opportunities in material flow through Value Stream Mapping, from receiving to final delivery.
Master Spare Parts List
We design and implement a structured master list to facilitate organization, search, and replenishment of critical spare parts.
Preventive Maintenance in SAP
We configure and manage preventive maintenance plans within SAP, aligned with spare part availability and scheduled tasks.
We launch new or relocated operations quickly and with control, minimizing risks and accelerating production start-up through a step-by-step ramp-up strategy.
Vertical Start-Up Strategy
Ensures stability from testing phase to steady production, speeding up the operational learning curve.
Initial Parameterization and Testing
We establish baseline conditions for new equipment, validating technical functionality and safety.
Monitoring and Adjustments
We supervise performance during initial runs to make real-time adjustments.
Progressive Ramp-Up
We gradually increase production capacity until the target volume is reached with consistent quality and efficiency.
Start of Regular Production
We formalize the transition to standard operations with controlled KPIs, trained teams, and validated procedures.
We present the Vertical Start-Up process through a 9-step approach, ensuring an efficient and successful transition.
We offer comprehensive solutions that not only improve operational efficiency but also boost productivity and reduce costs.
