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LEAN THINKING PRODUCTIVITY PROGRAMS
Lean Thinking is a unified Philosophy/System for Improving Productivity and Product Quality
The identification and elimination of waste from the value stream is the central theme of the Lean Thinking Philosophy. Lean Thinking is a dynamic constantly changing process dependent on the understanding and involvement of all of the company's employees. All employees must be trained to identify and eliminate waste from their work.
The Three Pillars of Lean Thinking:
- The Problem - Waste exists at all levels and in all activities.
- The Solution - The identification and elimination of Waste.
- The Who - All of the employees and departments comprising the organization.
Lean Thinking Systems are designed to Be Cleaner, Be Safer, Be Better Organized, Have Higher Morale, Produce Better Quality and Be More Productive.
Tap Resources has been doing training and the implementation of Lean Thinking for some time and at many suppliers. As we visited numerous sites and did training it became apparent to us that we needed to do something different if we were going to assist you in being successful in the implementation of Lean Thinking.
Because of our collective desire not to spend an inordinate amount of time in training session and spend more time in the actual implementation of Lean Thinking we take a different approach to the training and implementation. An example of a Lean Training session at other companies by other consultant would require 4 to 5 days of training in Value Stream Mapping that included several examples from other companies and considerable homework on these examples. We were searching for a better way to bring Lean Thinking to you.
The method we use is to do overview training for all employees and actually conduct implementation events around that training that is specific to you. Those implementation events will be done with a small select group of individuals who will then become the foundation for future events.
Successful implementation of Lean Thinking and the long term viability of the organization to continue utilizing the process require discipline. That discipline can be reinforced by the use of project management techniques and tools. Project plans with action item for accountable individuals with due dates are always a good way to maintain your discipline. Our training method includes the development of project plans and actions item for both the implementation events but also the follow-up on these events.
PRODUCTION EVALUATION AND RATIONALIZATION
Production Evaluation & Rationalization is done to assure that the right product is filled in the right cylinder at the right time at the lowest possible costs.
Goals/Objectives
Use Lean Thinking Principles to Provide Production Productivity and Reduce Product Losses
- Reduction in Production Costs of 20-30%
- Potential elimination of redundant production locations
- Facilitate improved On-Time and completion of Service to targeted 98%
- Decrease Product losses due to tank size, improper equipment and training while examining potential to eliminate some equipment
STEPS in Production Evaluation & Rationalization
- Identify Gaps after establishing Kan-Bans
- Size Manifolds appropriately
- Establish a waste-free strategy by locating assets and resources at point of work
- Establish workplace organization and visual controls
- Follow-up with Kaizen events to establish Best Practices
- Adopt Manpower Sizing Model based on Bench Marking and time study
- Evaluate and Analyze Production Losses
*For more information on Lean Thinking please read the article published in CryoGas International.
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DEVELOPING AN OPERATING PLAN
The managing of operations focuses on managing the processes and procedures to manufacture and distribute compressed gases and related equipment. Because a great deal of focus is on efficiency and effectiveness of processes, our operations management will include measurement and analysis of internal processes.
An operating plan central to success because It forces you to look at the big picture and the planning process is the vehicle that allows you to think creatively about what your workplace needs in order to be efficient and serve your customers.
The operating plan will consist of a schedule of events, programs, and responsibilities that details the actions in order to accomplish the goals and objectives of the larger organization.
A results oriented approach doesn't start with activities. It starts with a well-thought-out operating plan which really is the foundation for managing your operations.
You are going to be more successful if you have an operating plan because:
- Creating a plan forces you to consider your company's needs and strategic priorities. Experience tells us that meaningful outcomes are more likely achieved if they are linked to business priorities.
- It forces you to look at the bigger picture. All too often we become a slave to the activities we are performing and never consider the real impact they have on the service we provide and the profits that are delivered.
- A plan communicates your priorities to everyone. To your employees, to your sales representatives and ultimately to your customers through improved service.
- A plan gives your program continuity through personnel changes. Turnover is a fact of life and without written documents, a lot of hard work can be lost and progress stalled.
- A plan provides the energy to making things happen. The plan articulates the specific goals and objectives-the things that need to get done. It holds everyone accountable for their actions. The accountability created by developing the goals and objectives serve as a source of energy for everyone.
- Plans serves as a means to measure- and proves effectiveness - and improve. Because it captures both the present position and where you want to be in the future, it serves as an important tool for measuring change.
- Measurement and Evaluation - What are the measurements you need to make and how will you answer the question," How do we know if we have been successful?"
TAP Resources can work with you to develop an operating plan or to work with you to provide programs to make your operating plan successful.
*For more information on Operations Planning please read the article published in CryoGas International.
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CYLINDER ASSET MANAGEMENT
We can assist you to facilitate error free service by developing a program that assures the right number of the right product in the right cylinder is available.
Goals/Objectives
Produce the right product in the right cylinder
- > 98% On-time delivery
- 20% Reduction in total cylinder holdings
- Facilitate standardized offering of packaged products
- Reduction in day stocking factor (DSF)
- Defer Capital Expenditures
- Provide Measurements to manage their business at local and corporate level
TAP Resources will help you review and analyze sales and projected amount of sales. TAP will Identify opportunities for package standardization and Establish KAN-BANs for full and MT cylinder inventory
*For more information on Cylinder Management please read the article published in CryoGas International.
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PRODUCT LOSSES
TAP Resources estimates that your product losses for He, H2, Ar, N2, O2, UHP O2 at GT&S are 20-30% higher than the industry norm. This places you in a distinct disadvantage in the marketplace in which they are competing.
These losses are a result of several factors:
- Bad tank vacuums and maintenance
- Wrong size tank for usage
- Incorrect operating processes & procedures
- Training requirement for transfills
Bad tank vacuums and maintenance
TAP Resources recommends that an immediate inspection be done on all transfill tanks and that the vacuum level be checked. Attention should be given to assure that the pressure build circuit is turned off on all transfill tanks and a sign posted to notify operators not to open. This should become an annual inspection that looks at safety and tank performance. Interim requirements for maintenance should be requested by the location manager as needed. In addition, the safety relief and rupture relief valves must be piped out of the immediate area so that an operator can operate the diverter valve without comprising safety.
Wrong size tank for usage
TAP Resources recommends that a company wide assessment of Transfill storage tanks be completed as soon as possible to identify oversized and undersized tanks. Information required is tank size, product demand and product supplied on a monthly basis over the last 12 months. TAP Resources can perform an assessment and provide a proposed prioritized implementation schedule for tank change outs.
Incorrect operating processes & procedures
The following operating procedures should be adopted immediately at all location:
- Tank level and pressure reading should be recorded at the beginning and end of each day.
- Visually Inspect tank when doing readings, looking for frost spots especially in the morning.
- Production should be scheduled so that the liquid pumps are started a minimum number of times per day, preferably once.
- Pump cool downs should be a maximum of 15 minutes, siphon tanks 5 minutes.
- Pumps should be valved closed when pump is not running so as to minimize pressure build-up due to the heat created while circulating liquid through the pump.
- Transfill tanks should be operated at 60pisg and a notice should be posted to top fill the tanks to maintaining that pressure. Written notice should be given to supplier that this is a requirement for the tank.
Training requirement for transfills
A training program in tank operation and loss management should be conducted as soon as possible. In addition to the aforementioned areas, attention should be given to:
- Reorder points established to minimize deliveries and obtain coldest product possible.
- Reconciliation process for delivery tickets versus gauge deliveries to identify discrepancies. Liquid trailer meters are historically inaccurate.
TAP RESOURCES has a program to assist you in this very important area.
*For more information on controlling product losses and the financial impact pleased read the article published in CryoGas International.
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SAFETY PROCESS MANAGEMENT
A Safety Process provides the tools for, local management to be effective in coaching and continuing to improve the safety performance and safety culture of the organization.
Goals/Objectives
- Comply With OSHA Requirements
- Comply With EPA Requirements
- Reduce and Manage Preventable Injuries and Vehicle Accidents
- Increase Employee Involvement and Ownership in Safety
- Develop Appropriate KPI's
- Establish Customer Safety Guidelines
STEPS in Safety Process Management
- Review CURRENT Safety Process for Gaps
- Recommend and Implement the TAP Process that includes:
- Site Specific Safety Action Plans
- Compliance with Government Regulations
- Training Elements and Periodic Schedule
- Program Implementation Plan
- Workbook including process forms
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SUPPLY CHAIN RATIONALIZATION
Supply chain rationalization, unlike incremental change, guarantees the biggest improvement in customer service, productivity and cost reduction.
Goals/Objectives
Produce the right product in the right container at the right location which is closest to the majority of customers.
- 20-30% Cost Reduction
- Defer Capital Expense
- Improve Cycle time for Order to Delivery 5X to 10X
- > 98% On Time Delivery
- Reduce Landed Costs and Measure Components
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DISTRIBUTION OPTIMIZATION
Why Do Distribution Optimization?
To achieve > 98% On-Time Delivery at lowest achievable cost.
Goals/Objectives
- > 98% On-Time Delivery
- Reduce distribution costs by 20%
- Rationalize equipment assets
- Validate lowest equipment maintenance costs with high reliability
*For more information on Distribution Optimization please read the article published in CryoGas International.
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ENGINEERING & EQUIPMENT SUPPORT
TAP will provide Engineering Services to address the equipment required to store and regulate the product to the use point:
- Gas Storage Supply System Design
- Transfill Design and Modifications
- Telemetry
- Civil Engineering Requirements
- Equipment Selection & Purchases
- Technical Training
- Safety Assessments
- Gas Optimization at Customers
TAP Resources utilizes Professional Engineers with 20+ years of experience to provide these services.
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SECURITY VULNERABILITY ASSESSMENT
USA Businesses need security to provide protection from external and internal threats of terrorism.
We can develop a guidance program for employees, facilities, transportation, customers and information technology.
Security from external and internal threats of terrorism including:
We will work with your company to:
- Identify Your "Chemicals of Concern" List
- Develop a Customer Qualification Procedure
- Operations Security Vulnerability Analysis (SVA)
- Reducing Risk Utilizing Multiple Levels of Protection
- Transportation Security Guidelines
- Implementation of DOT HM-232 (Security Training)
- Recommendations to Address Security of "Chemicals of Concern" at Customer Sites
We can develop a guidance program for employees, facilities, transportation, customers and information technology.
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FDA COMPLIANCE
TAP Resources can implement Compliance programs for Product Supply and Transfill Validation including:
- Transfill Validation
- Comprehensive Checklist of Requirements
- Conduct Audits at Transfills
- Implement Compliance Programs
- Provide Procedures to Conduct Self-Audits
- Provide Assistance in Correcting Non-Conformance or Violations
- Provide Training as Required
- Rationalize Supply Chain
- Product Supply - Administrative and Technical Assistance
- Fill Procedures and Processes
- Documentation Requirements
- Production / Distribution Evaluation
Why Have a Compliance Program?
The Federal Food, Drug, and Cosmetic Act requires that facilities that fill prescription drug medical cylinders or dewars register with the FDA. They require that these facilities be subject to agency inspections, to ensure compliance with current Good Manufacturing Practices.
You Need To
- Comply With FDA Compliance Requirements
- Establish Procedures and Check Lists of Requirements
- Perform Self-audits
STEPS in FDA Compliance
- Conduct Audits at Transfills to Determine Needs
- Document Non-Conformance or Violations
- TAP Can Provide
- Transfill Validation
- Comprehensive Checklist of Requirements
- Provide or Up-date Fill Procedures and Processes
- Provide Training as Required
- Validate Chain of Custody for Supply Chain
- Product Supply - Administrative and Technical Assistance
- Documentation Requirements
- Production / Distribution Evaluation
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SPECIALTY GAS SALES & PRODUCTION "TOTAL SOLUTION"
TAP will provide Sales/ Marketing, Engineering and Analytical Services to address the processes, procedures and equipment required to sell, manufacture and certify specialty gases. We can provide all and any of the following:
- Market Evaluation and Economic Analysis
- Gas Supply System Designs
- Gas Supply System Installations
- Transfill Processes, Transfill Procedures and Training
- Analytical Equipment Selection
- Analytical Equipment Purchases
- Analytical Equipment Installation and Training
- Sales and Marketing Training
TAP offers a Complete Package utilizing:
- Experienced Specialty Gas Marketing Professionals.
- Professional Engineers with 20+ years experience.
- High Performance Analytical Equipment specifically designed to meet your needs, installed at your location, training by instrumentation specialists, and continuous support.
- Marketing and Sales Training to support your investment and promote success.
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MARKETING & SALES MANAGEMENT
TAP can help you evaluate and improve your marketing and sales programs. Our sales and marketing experienced experts can provide consulting and implementation to assist you in growing your sales, focusing your team, exploring new markets, developing markets for new products, new sales channels and expanding into new geographies.
| Strategic Marketing |
Sales Training |
| Channel Development |
Consultative Sales |
| Lead Generation/Development |
Sales Territory Management |
| New Business Development |
Competitive Intelligence |
| Sales Productivity Review |
Strategic Alliances |
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MERGER AND ACQUISTION MANAGEMENT
TAP will help plan and monitor integration of service processes and customer data as well as plan and monitor supply chain integration
- Protect Productivity
- Employee Communications
- Control Amount of Destabilization
- Quick Impact Training
- Plan and Monitor Project to Transfer and Integrate Customer Data
TAP will help you start managing the transition when the deal is announced. Our years of experience have helped us develop a proven framework to ensure a smooth transition. We will assure that you:
- Are Realistic About Cultural Differences
- Give Your Workforce a Proper Merger Orientation
- Take Care of the "Me" Issues
- Keep the Focus on Clients and Your Marketplace
- Make Everyone Responsible for Merger Success
There is no "school solution" for merger integration, but we have learned a lot over the years about what works and what does not when companies are being acquired and merged. We know you can benefit from our experience.
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INTERIM MANAGEMENT
TAP Recourses has industry - leading expertise at providing operations managers that can be deployed rapidly to take charge of day to day operations. These highly skilled leaders have 20+ years of managing all aspects of the Industrial Gas business. We can quickly "stabilize" the business unit, install work processes, and begin initiatives that advance performance.
- Management Team Effectiveness
- Production Efficiencies
- Product Quality
- Employee Management
- Safety Programs
- Operations Planning
- Supply Chain/Inventory Management
- Cost Controls
- Lean Thinking
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ASSET RECOVERY
TAP Resources asset recovery services will obtain the highest return on your industrial gas equipment that no longer meets your needs.
With years of experience in the industrial gas asset recovery business, we can help your company determine and leverage the value of your unwanted equipment.
Why use TAP for asset recovery?
- Tightly controlled processes and business practices
- Many years of experience with multi-vendor products
- Global capabilities
- Technology refresh options for analytical equipment
- Fair market value
- Disposal of obsolete assets
- Transportation and Logistics
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