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Liberty Productivity Improvement
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PROJECTS and COURSES

Per "project" a short indication of the company or business (unit) is given plus a condensend description of the work or activities and techniques and tools (in blue) used

Company or Business (unit)
Education and Training

Description

Connect Group, Kampenhout (B)
Consulting to management

On request of management of Connect Group at Kampenhout (B), consulting to management in the fields of standard times, hour tarifs and structure of cost prices.

Brabantia BV, Overpelt, Belgium
Education lower management

Education and awareness of lower management in “Smart Working”. A brief introduction on Work Study and “method study on the job floor” for practical knowledge in improvement techniques.

Brabantia BV, Overpelt, Belgium
Education staff, international

Education and awareness of staff workers in "Method improvement, Times and Losses". A brief introduction on  Work Study (method study and time study) and some other work study techniques. Because of the participation of an employee from Brabantia Latvia, the course material and the course language was English.

Giant Europe Manufacturing BV,
Lelystad
VWF-course
 

A VWF course, preceded by an introduction to Work Study, to Elimination of Wast, and to Method study and Time study, was set up and given for 7 employees of Giant Europe Manufacturing at Lelystad. The purpose was to provide the participants with some basic knowledge on work study to enable them to come up with some better methods to execute the tasks in the right order at the right place or location and to better understand the workers time spending during the day, by using standard times and loss factors.
Course duration: 5 days from ca 08.30 hrs till ca 17.30 hrs. This was an in-company training.

Suplacon Metal Plate Processing
BV, Emmeloord
Preliminary view
 

Suplacon was looking for (calculation)models to be used to determine machine times and manual operation times. The times must then be checked out and validated. Also Suplacon was looking for a Work-Factor system to determine the standard (normal) manual times and man times. Problem formulation, possibilities and solutions were discussed.

Essilor Benelux, Zevenaar
Basic Work-Study course
 

A Basic Work Study Courses, including VWF, was set up and given for emloyees of Essilor at Zevenaar. The purpose was to provide the participants with some basic knowledge on method study and time study to enable them to come up with some better methods to execute the tasks in the right order at the right place or location and to better understand the workers time spending during the day, by using standard times and loss factors.
Course duration: 5 days from ca 08.30 hrs till ca 20.00 hrs. This was an in-company training.

Brabantia International BV,
Zhuhai-China
Basic Work-Study course
 

A Basic Work-Study course was set up and given for employees of Brabantia Hong Kong and Greenwood Houseware Zhuhai, China, partner of Brabantia. The aim was to introduce knowledge on work study and work analysis, especially on the fields method study and time study to the participants, in order to be able to develop better working methods and better usage of working time to decrease the material rejects and production losses considerably and improve the overall productivity. Included was a VWF appreciation course.
Course duration: 4 days from ca 08.30 hrs till ca 20.30 hrs and 1 day from ca 08.30 hrs till 16.30 hrs; as an in-company training.
Participants came from Brabantia Hong Kong, Greenwood Houseware, Metal Stamping Technology and Philips DAP Zhuhai.

Bakker Barendrecht BV
Small pilot assignment to determine
BT, ST and estimate for CT.

Small pilot assignment to establish task times (basic times) for 2 products (prescriptions) using Bedaux system (stopwatch and tempo rating). By means of obervations and measurements a factor for R+PC was calculated and consequently a task setting (standard time) was calculated. The organisational and technical losses were estimated by interviewing operators and staff and with the existing rejectfactor a good estimate of the “Good products output per day” was derived.

Hamstra Blinds, Almere
Pilot study to the flow of the
production process and to set
standards of work.
 

Initial assignment: Observe the production process and present a proposal for a pilot to determine and normalize all processes and manufacturing steps of 1 actual product. Describe all observations as good as possible and present possible improvements.
The production process was mapped out and determined using process schemes and the
Flow Process Chart, FPC, calculating also various PI’s as throughput time, WiP and Effectivity.
Using observation and method study a description was presented of improvements on working method, ergonomics, technical supporting tools and organization per workplace, group and department.
Based on the real goods flow of the department of the previous year some alternative
lay-outs were presented  to improve a better flow of goods.
To further improve the productivity, many proposals were presented as lowering batch sizes and combining the many different small “batches”.

Philips Vitrite, Lighting,
Middelburg
Method improvement and standards
for quality department.
Standards for inspection tasks.
 

Determine and describe the present situation of the way of working, the organization and the time standards (norms) used in the quality control department. In the past, these normal times were established with Stopwatch method, in order to achieve starting (initial) values for performance, output and production times.
By observation and method study improvements of working methods, ergonomics, technical auxilary tools and organization were described and immediately implemented (sometimes partly), initiated or started and concluded.
In the 2nd phase time standards (norms) were set up and established for all inspection tasks using the
Work-Factor MENTO-FACTOR Compact system. From these new time standards, task settings and standard times were calculated to enable better planning and performance assessment by the worker as well as the management.

Philips Turnhout, Lighting
Increase output and
improve productivity
 

Situation: A manual production line of 6 production steps with 1+2+2+4+2+2=13 work stations with buffers cq decoupling points between the production steps. Initial assignment: Improve and balance out in such a way that lesser people produce the same output at the same level of quality.
Because of fast increasing product demand and new higher levels of quality, the initial assignment was refrased into: change the existing production system gradually from a “push” system into a “pull” system, while making the production line far better balanced with just 1 decoupling point (d.p.) and 1 buffer. Use improvements and flexible work force of the workers.
This resulted in an increase of the production output from 1700 pcs per shift to more than 3700 pcs per shift at a simultaneously increase of the productivity. This all was achieved by using
method improvement on 3 levels, flow line principles, techniques of Job Floor Management and time study with Bedaux method and Ready WORK-FACTOR, RWF.
Staff members of different departments were educated and trained in method study and continious improvement techniques.
An
Excel computerprogram was developped and installed for workers, staff members as well as for management to make and follow up on planning and reality of production numbers, working hours of workers and staff and quality per worker, per shift, per week and per quarter.

Philips DAP, Drachten
TPC and DC Education & Training

Education and training of  employees from ISG/ICE and O&E employees in cost prices and costprice calculations, TPC, and decision calculations w.r.t. investments, DC.

Philips DAP, Drachten
WF Training and WF-commissioner

Education and training of  employees from ISG/ICE and O&E employees in WORK-FACTOR, RWF and VWF. Act as a sounding board for WF-instructor and commissioner for WF-examinations on behalf of the WORK-FACTOR Council.

Top Flora International, Flowers,
Aalsmeer
Training and reduction of
throughput time

Education and training of staff members in production and production-support on the basic principles of work-study, especially the 7 Tools and method study with Flow Process Chart, FPC. Coaching workers at the FPC-practical assignment to improve and decrease the throughput time and lowering buffers and stocks.

Brabantia BV, Overpelt, Belgium
Training lower management
 

Education, training and creating awareness of lower staff members towards "Smart Working". A brief introduction was given into Work-Study (method study and time study) and a variety of WS-techniques. Insight in the relation between costs and the cost price was broadened. All in relation with the own  NEAT-ly working approach (Neatly, Efficiëntly, Accurately and Timely).

Premotec, Dordrecht
Education O&E-er

Education, training and coaching of a staff member in costprice calculation (TPC) and decision calculation (DC).

Krohne, Dordrecht
Reduction of throughput time
 

By using Flow Process Chart, FPC, analyzing the product flow of some characteristic production lines. A considerable decrease of throughput time and reduction of WiP was made possible by method improvement on each work station, better balancing of work content, decreasing batch sizes and improvement of the work discipline.

KPN Broadband Networks,
The Hague
Awareness Business like approach.
 

Introducing to staff members the way of working (systems and methods) during the production process in a normal industrial plant by using work study (method study (FPC) and time study (VWF)); the direct relation of the operational - and work study factors with the cost price and the difference between cost price thinking and business economical thinking was made clear. All this with respect to and in reflection of their own KPN way of thinking.

Philips Roosendaal, Lighting
Efficiency improvement
 

Investigation into the availability and work force of personel and into the up-time and disturbances of the TL-production machines by using Multi Moment Observation, MMO, technique. Using method study further improvements were indicated and implemented.

Technotion BV, Management,
Almelo
Cost price system improvement
 

Assessment of the existing cost price system, TPC, and renewed definition and determination of the various parts of the cost price and allowance factors. Consequently, a better insight and understanding was created on the cash flows and costs and revenues. Also, a distinction was created between the present products and the new future high tech products.

PBF, Electronics, Almelo
Reduction of throughput time
 

Mapping and analyses of production lines with Flow Process Chart, FPC. Presenting recommendations for method improvements, better balancing, decreasing stocks and buffers (WiP) and reduction of batch sizes.

Fuji Photo Film BV, Emulsions,
Tilburg
Efficiency improvement
 

Mapping all operations and handling including all safety aspects of the department for special emulsions. Then establish the way of working and the future way of working with the proper utilization of manpower to execute all tasks needed, inclusive illness, absence, leave, etc. The operations and tasks were mostly mapped using the Flow Process Chart, FPC, technique..

Philips Winterswijk, Lighting
Indoor: Time standards
 

Mapping all manual work stations in production: method study on work station on motion level. Using Ready WORK-FACTOR, RWF, all products on b.o.m. level and all necessary corresponding movements and motions were analyzed and standardized on factory standard tempo. A database of standard times on bom-level was set up in such a way that existing and future products and product lines can simply be set up, balanced and analyzed.
Workers and staff members were educated and trained.

Philips Winterswijk, Lighting
Outdoor: Balancing production lines
 

Using Ready WORK-FACTOR, RWF, all motions and movements on all work stations were analyzed. This resulted in a huge method improvement and a far better balancing of the stations. Resulting in an increase of production output of at least 25%.

Philips Winterswijk, Lighting
Reduction of change-over-times
 

Simplifying and standardize (norm setting) the change-over time on the 3D-machine from product A to product B. The change-over time was reduced from ca 20 minutes to ca 10 minutes by using Single Minute Exchange of Die, SMED, technique.

Philips Oss, Elektronics
Analysis of production losses
 

Using Multi Moment Observation, MMO, technique, analyses were made of up-time and the various losses during production of 6 inserter machines, 4 onserter machines and some reflow-production lines with up to 6 manual pre-assembly work stations, inspection and packing. Many improvements were prersented and implemented.

Standard course / training

Description

Work-Study, WS
Certified Education and Training

Certified = Part of IBIE-A
 

Course duration: 5 (6) periods of 3 days being 5 (6) x 8 = 40 (48) day shifts, exclusive time for the practical assignment.
Experience: Many courses for Dutch speaking in Achel (B), Steensel, or on the plant site of the company, i.e.  Philips Winterswijk. For Engels speaking in Thailand (Bangkok), Poland (Pita, Ketrzyn, Pabianice, Bielsko-Biata, Kwidzyn, Skierniewice), Hungary (Szekesfehervar), Austria (Vienna). For DAF BV around and in the area of Eindhoven.
WS is inclusive VWF or UAS.

Basic course Work-Study, BWS
 

Course duration: 3, 4, 5, 6 or more days of 2 or 3 day shifts each,  on request, in periods of 2 or 3 days. WS subjects and mudules on request and after mutual consultation. Language: Dutch or English. Location: in-company.
Experience: see above.

Technical Pre-Calculation, TPC
Cost Price Pre-calculation
Certified Education and Training

Course duration: 3 periods of 2 days being 3 x 4 = 12 day shifts, exclusive time for the practical assignment and examination. Language: Dutch or English. Location: in-company.
Experience: Many courses for Dutch speaking at Eindhoven and DAF (around Eindhoven). For English speaking in Thailand (Bangkok), Poland (Pita), ..

Decision Calculaties, DC
Investment decisions
Certified Education and Training
 

Course duration: 3 periods of 2 days being 3 x 4 = 12 day shifts exclusive time for the practical assignment and examination. Language: Dutch or English. Location: in-company.
Experience: Many courses for Dutch speaking at Eindhoven and DAF (around Eindhoven). For English speaking in Thailand (Bangkok), Poland (Pita), ..

Very easy WORK-FACTOR,
VWF
Certified Education and Training

Course duration: 1 period of 3 days being 3 x 2 = 6 day shifts, exclusive examination and exclusive 2-hands analysis, VWF for Designers and Work Planners, and VWF software. Language: Dutch or English. Location: Mostly on plant site in The Netherlands or abroad.
Experience: Many courses o.a. at Philips Drachten, Brabantia (The Netherlands, Belgium and China), Philips Winterswijk.

Ready WORK-FACTOR, RWF
Certified Education and Training

Course duration: 3 periods of 2 dys being 3 x 4 = 12 day shifts, exclusive examination and exclusive 2-hands analysis, RWF for Designers and Work Planners, and RWF software.
Language: Dutch or English. Location: Mostly on plant site in The Netherlands or abroad.
Experience: Many courses o.a. at Philips Drachten, Philips Hoogeveen, Philips Turnhout. For English speaking in Poland (Pita).

In-company, modified or specific
educations and trainings

Course duration: after consultation, possibly also during evenings and week-ends.
With or without practical assingment, with or without diploma.
Mostly in the area or on site of the plant or company.
In Dutch or English.
For experience see above.

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