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Flow Management Technology   a whole new dimension to “Lean” thinking BTM Business Technology Management, Inc. 50 Robert Treat Parkway Milford, CT  06460 Phone: (203) 877-2261 Fax: (203) 874-4242 Email: info@btminc.com Web: www.btminc.com
Over the past 10 + years “Lean” principles, based on the Toyota Production System, have been taught and implemented as the answer for achieving long term profitability.  With all the time, energy, money and effort invested,  are you dissatisfied with the bottom line profits?
“ Despite the huge influence of the Lean movement … most attempts to implement Lean have been fairly superficial.  The reason is that most companies have focused too heavily on tools such as 5S and just-in-time,  without understanding Lean as an entire system …”  The Toyota Way , McGraw Hill Jeffrey K. Liker, Ph.D.  Professor of Industrial and Operations Engineering University of Michigan
In most cases, improvement initiatives turned into   Islands  of success   not  translating into equal success for the whole business JIT 5S CELLS Lean Principles TOC 6 SIGMA Kaizen Events
[object Object],[object Object],[object Object],Let’s explore how these may affect your business
Every flow process can be depicted as a series of interconnected resources - each acting as an  Input/Output device This view applies to the flow through machines, departments, sections, divisions and every part of the company Computer Specifications Software Tools People Computers & Programs Tools &  Supplies Electricity Dependencies Dependencies Resource B Resource A Dependencies Dependencies
Improving the output of one Resource may create a   bottleneck  at the next one.   While local indicators show   improvement at Resource A, the whole business may see marginal or no improvement. Work Build-up Resource B Resource A Local or Global? In other words, dealing with a subset of the business may not yield improvements for the whole   Computer Specifications Software Tools People Computers & Programs Tools &  Supplies Electricity
[object Object],[object Object],[object Object],[object Object],Many improvement initiatives focus on the Manufacturing process where things are most visible.  However, it is only part of the entire business flow.  Local or Global? Sales Marketing Engineering Subcontracting  Purchasing Logistics Vendors Distribution Warehousing Customer service Receivables  Invoicing  WIP Finished Goods M a n u f a c t u r i n g Raw Materials D C B A
[object Object],[object Object],[object Object],[object Object],[object Object]
Let’s move now to addressing the other major obstacle that plagues every organization - the   Wave Phenomenon
A small disruption somewhere at the beginning of the process will intensify into a huge wave at the end of the chain due to random disruptions coupled with Murphy’s Law Internal and External disruptions cause random waves which disrupt every business flow The Wave Phenomenon
Random Dynamics The Chaotic Behavior Of A Flow System INPUT A B Erratic Internal Disruptions Associated With Each Resource PLANNED OUTPUT Intensified Random Fluctuations ACTUAL OUTPUT
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],The impact of the Wave Phenomenon leads to the following problems:   ,[object Object],[object Object],[object Object],[object Object],[object Object]
What’s needed is a methodology that encompasses the entire organization end-to-end, overcomes the impact of the Wave Phenomenon and a  simple way  to optimize the flow for profit maximization Sales & Marketing Engineering Logistics and Purchasing Production Line A Production Line B Subcontracting Warehousing Distribution Customer Service Receivables Invoicing Manufacturing Information Systems C u s t o m e r s C u s t o m e r s Flow Management Technology   does just that!
By viewing the organization as a total flow system, analyzing disruptions, the effects of Murphy's Law, and applying the principles of fluid dynamics and systems control (as in hydraulic systems),  Flow Management Technology  breaks boundaries as well as bottom line performance! Let’s look at key concepts and building blocks of   Flow Management Technology (FMT)   and how it can help achieve long-term success. A B C D Feedback Loop Input Valve Middle Valve vacuum effect vacuum effect Valve Resource Valve Resource Strategic Buffer DEPARTMENT RESOURCE MACHINE DEPARTMENT Customer Orders Throughput Sales Manufacturing Lead Time Overall Lead Time THROUGHPUT Reserved Capacity Reserved Capacity
It is a methodology to analyze the entire process by viewing resources as Input-Output devices and their interdependencies.  It uses a Flow Tube Analogy to develop a simple   Business Flow Model   for achieving tight control, quick reaction and robust performance A B C D Output Tube Length = Lead Time Input Tube Diameter =  Flow Rate A B C D
[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object],[object Object]
[object Object],[object Object],[object Object],Valve Resource A B Input Throughput Strategic Time Buffer Strategic Buffer Max Min
[object Object],[object Object],Strategic Buffer Valve Resource A B Strategic Buffer Valve Resource Measure Output Measure Output Measure Inventory & Lead Time Feedback Loop Market Demand
Business Flow Model Example Lead Time 2  2 Weeks LT Buffer 1 Day Lead Time 3  1.5 Weeks LT Buffer 2 Days Lead Time 1 3 Days  A B C D Finish Ship Pack Main Valve Valve Strategic Buffer Customer Orders Order Processing RM  Strategic Buffer Orders Shipping Strategic  Buffer H Max Min Release Valve Raw Materials E F G #1 #2 #3
Pre- Production Processes Raw Material Manufacturing Finished Goods Customer Orders Delivery Lead Time Pre- Prod. Proc. RM Mfg FG Customer Orders Delivery Lead Time The results of Continuous Improvement using FMT Pre- Prod. Proc. RM Mfg FG Customer Orders Delivery Lead Time Shorter Lead Time Lower Inventory Higher Throughput Lower Cost Better Quality Higher Profitability
It is not another copycat of Japanese techniques.  It doesn’t require years and years of restructuring American jobs, careers, functions and firms along product value streams. It doesn’t require adopting Japanese terms and tools like Kaizen, Haijunka, Muda, Poke Yoke, Kan Ban, Judoka, Andon, etc.  Flow Management Technology was created for the American free enterprise system to generate short and long term profitability.  In summary, implementing Flow Management Technology is a low cost, down to earth, simple and quick process.  It will bring your company substantially better performance from your current resources. It will make your business leaner than “Lean” Regardless of where you are,   Flow Management Technology  will move you forward Unprofitable Marginally Profitable Profitable Highly Profitable
“ For better bottom-line performance, you should have a new perspective of your business as a flow mechanism.” “ FMT users report that they achieve results of 75% net profit increase, 50% plant throughput boost, and 70% lead-time reduction in a matter of months.”  “ Our throughput rate on a three-shift operation was around 35 million lb/month; now it’s up to 50 million lb/month.  We get more out, and more on time." Per the VP and General Manager Commonwealth Aluminum  Paul C. Miller Editor of Metalfax Magazine “ The effectiveness of FMT can be shown in many ways, such as reduced inventory levels, improved cash flow, shorter manufacturing leadtimes, better customer service, and less overtime.  But the single most important sign that the system is working is profit generation.” “ FMT produced a 50% reduction in raw-material inventory, reduction in lead times from eight weeks to eight days, an increase in throughput of 142%, and the total elimination of late deliveries.  Moreover, FMT is credited with doubling corporate profits in the first year.” Per The Chairman of North American Products  Robert Eade Contributing Writer, Tooling and Production Magazine  Testimonials
“ In the area of product, throughput has increased by 70 percent without a change in inventory. 205 past-due orders… have been taken down to zero in four months.  Further, quality has improved: Customer complaints dropped from one a day to one a month.” Per Black & Decker’s General Manager   Robin P. Bergstrom, Editor-at-Large Production Magazine “ Flow Management Technology has helped countless companies replace chaos with order in directing their manufacturing processes, from order entry and raw material inventory through in-process production planning to shipping finished goods on time.” Stanley J. Modic, Editor-in-Chief Tooling and Production Magazine Testimonials
Business Technology Management, Inc. (BTM) was founded in 1987, in Milford, Connecticut.   BTM is the company that developed Flow Management Technology.  Over the years, BTM’s highly experienced group of professionals have taught, coached and assisted in Flow Management Technology implementations at a broad spectrum of industries, leading to one success story after another. Such industries include automotive, electronics, apparel, aerospace, tools & equipment, as well as service industries.  Other applications include Logistics Supply Chain, Purchasing, Product Development, Project Management, etc.  BTM’s founder, Mr. Itzik Kostika, is the author of the training book  Breaking Out of the Box , as well as a series of articles published in a leading Trade Magazine.  Mr. Yaron Lew, BTM’s General Manager, is the author of several articles on Operations Improvement and his White Papers on  Reducing Cost and Increasing Profitability  as well as  Focusing Lean Efforts in a Down Economy   were published in IndustryWeek’s website. BTM
BTM Business Technology Management, Inc. 50 Robert Treat Parkway Milford, CT  06460 Phone: (203) 877-2261 Fax: (203) 874-4242 E-mail :  [email_address] Website: www.btminc.com For further information and to explore the potential for your company, please contact us

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FMT New Dimension To Lean Thinking

  • 1. Flow Management Technology a whole new dimension to “Lean” thinking BTM Business Technology Management, Inc. 50 Robert Treat Parkway Milford, CT 06460 Phone: (203) 877-2261 Fax: (203) 874-4242 Email: info@btminc.com Web: www.btminc.com
  • 2. Over the past 10 + years “Lean” principles, based on the Toyota Production System, have been taught and implemented as the answer for achieving long term profitability. With all the time, energy, money and effort invested, are you dissatisfied with the bottom line profits?
  • 3. “ Despite the huge influence of the Lean movement … most attempts to implement Lean have been fairly superficial. The reason is that most companies have focused too heavily on tools such as 5S and just-in-time, without understanding Lean as an entire system …” The Toyota Way , McGraw Hill Jeffrey K. Liker, Ph.D. Professor of Industrial and Operations Engineering University of Michigan
  • 4. In most cases, improvement initiatives turned into Islands of success not translating into equal success for the whole business JIT 5S CELLS Lean Principles TOC 6 SIGMA Kaizen Events
  • 5.
  • 6. Every flow process can be depicted as a series of interconnected resources - each acting as an Input/Output device This view applies to the flow through machines, departments, sections, divisions and every part of the company Computer Specifications Software Tools People Computers & Programs Tools & Supplies Electricity Dependencies Dependencies Resource B Resource A Dependencies Dependencies
  • 7. Improving the output of one Resource may create a bottleneck at the next one. While local indicators show improvement at Resource A, the whole business may see marginal or no improvement. Work Build-up Resource B Resource A Local or Global? In other words, dealing with a subset of the business may not yield improvements for the whole Computer Specifications Software Tools People Computers & Programs Tools & Supplies Electricity
  • 8.
  • 9.
  • 10. Let’s move now to addressing the other major obstacle that plagues every organization - the Wave Phenomenon
  • 11. A small disruption somewhere at the beginning of the process will intensify into a huge wave at the end of the chain due to random disruptions coupled with Murphy’s Law Internal and External disruptions cause random waves which disrupt every business flow The Wave Phenomenon
  • 12. Random Dynamics The Chaotic Behavior Of A Flow System INPUT A B Erratic Internal Disruptions Associated With Each Resource PLANNED OUTPUT Intensified Random Fluctuations ACTUAL OUTPUT
  • 13.
  • 14. What’s needed is a methodology that encompasses the entire organization end-to-end, overcomes the impact of the Wave Phenomenon and a simple way to optimize the flow for profit maximization Sales & Marketing Engineering Logistics and Purchasing Production Line A Production Line B Subcontracting Warehousing Distribution Customer Service Receivables Invoicing Manufacturing Information Systems C u s t o m e r s C u s t o m e r s Flow Management Technology does just that!
  • 15. By viewing the organization as a total flow system, analyzing disruptions, the effects of Murphy's Law, and applying the principles of fluid dynamics and systems control (as in hydraulic systems), Flow Management Technology breaks boundaries as well as bottom line performance! Let’s look at key concepts and building blocks of Flow Management Technology (FMT) and how it can help achieve long-term success. A B C D Feedback Loop Input Valve Middle Valve vacuum effect vacuum effect Valve Resource Valve Resource Strategic Buffer DEPARTMENT RESOURCE MACHINE DEPARTMENT Customer Orders Throughput Sales Manufacturing Lead Time Overall Lead Time THROUGHPUT Reserved Capacity Reserved Capacity
  • 16. It is a methodology to analyze the entire process by viewing resources as Input-Output devices and their interdependencies. It uses a Flow Tube Analogy to develop a simple Business Flow Model for achieving tight control, quick reaction and robust performance A B C D Output Tube Length = Lead Time Input Tube Diameter = Flow Rate A B C D
  • 17.
  • 18.
  • 19.
  • 20. Business Flow Model Example Lead Time 2 2 Weeks LT Buffer 1 Day Lead Time 3 1.5 Weeks LT Buffer 2 Days Lead Time 1 3 Days A B C D Finish Ship Pack Main Valve Valve Strategic Buffer Customer Orders Order Processing RM Strategic Buffer Orders Shipping Strategic Buffer H Max Min Release Valve Raw Materials E F G #1 #2 #3
  • 21. Pre- Production Processes Raw Material Manufacturing Finished Goods Customer Orders Delivery Lead Time Pre- Prod. Proc. RM Mfg FG Customer Orders Delivery Lead Time The results of Continuous Improvement using FMT Pre- Prod. Proc. RM Mfg FG Customer Orders Delivery Lead Time Shorter Lead Time Lower Inventory Higher Throughput Lower Cost Better Quality Higher Profitability
  • 22. It is not another copycat of Japanese techniques. It doesn’t require years and years of restructuring American jobs, careers, functions and firms along product value streams. It doesn’t require adopting Japanese terms and tools like Kaizen, Haijunka, Muda, Poke Yoke, Kan Ban, Judoka, Andon, etc. Flow Management Technology was created for the American free enterprise system to generate short and long term profitability. In summary, implementing Flow Management Technology is a low cost, down to earth, simple and quick process. It will bring your company substantially better performance from your current resources. It will make your business leaner than “Lean” Regardless of where you are, Flow Management Technology will move you forward Unprofitable Marginally Profitable Profitable Highly Profitable
  • 23. “ For better bottom-line performance, you should have a new perspective of your business as a flow mechanism.” “ FMT users report that they achieve results of 75% net profit increase, 50% plant throughput boost, and 70% lead-time reduction in a matter of months.” “ Our throughput rate on a three-shift operation was around 35 million lb/month; now it’s up to 50 million lb/month. We get more out, and more on time." Per the VP and General Manager Commonwealth Aluminum Paul C. Miller Editor of Metalfax Magazine “ The effectiveness of FMT can be shown in many ways, such as reduced inventory levels, improved cash flow, shorter manufacturing leadtimes, better customer service, and less overtime. But the single most important sign that the system is working is profit generation.” “ FMT produced a 50% reduction in raw-material inventory, reduction in lead times from eight weeks to eight days, an increase in throughput of 142%, and the total elimination of late deliveries. Moreover, FMT is credited with doubling corporate profits in the first year.” Per The Chairman of North American Products Robert Eade Contributing Writer, Tooling and Production Magazine Testimonials
  • 24. “ In the area of product, throughput has increased by 70 percent without a change in inventory. 205 past-due orders… have been taken down to zero in four months. Further, quality has improved: Customer complaints dropped from one a day to one a month.” Per Black & Decker’s General Manager Robin P. Bergstrom, Editor-at-Large Production Magazine “ Flow Management Technology has helped countless companies replace chaos with order in directing their manufacturing processes, from order entry and raw material inventory through in-process production planning to shipping finished goods on time.” Stanley J. Modic, Editor-in-Chief Tooling and Production Magazine Testimonials
  • 25. Business Technology Management, Inc. (BTM) was founded in 1987, in Milford, Connecticut. BTM is the company that developed Flow Management Technology. Over the years, BTM’s highly experienced group of professionals have taught, coached and assisted in Flow Management Technology implementations at a broad spectrum of industries, leading to one success story after another. Such industries include automotive, electronics, apparel, aerospace, tools & equipment, as well as service industries. Other applications include Logistics Supply Chain, Purchasing, Product Development, Project Management, etc. BTM’s founder, Mr. Itzik Kostika, is the author of the training book Breaking Out of the Box , as well as a series of articles published in a leading Trade Magazine. Mr. Yaron Lew, BTM’s General Manager, is the author of several articles on Operations Improvement and his White Papers on Reducing Cost and Increasing Profitability as well as Focusing Lean Efforts in a Down Economy were published in IndustryWeek’s website. BTM
  • 26. BTM Business Technology Management, Inc. 50 Robert Treat Parkway Milford, CT 06460 Phone: (203) 877-2261 Fax: (203) 874-4242 E-mail : [email_address] Website: www.btminc.com For further information and to explore the potential for your company, please contact us