Total Systems
Development, Inc.
Phone:
859.543.9090
WEB
Site: www.leanmanufacturing.com
I Executive Summary
Total Systems Development,
Inc. (TSD) is an
international manufacturing engineering consulting firm specializing in the
design, development, implementation of and training in lean systems (process
improvement). Throughout a nearly decade
of operation, TSD has consistently provided clients with tangible value, both
short and long-term, resulting in significant and measurable savings, increased
productivity and enhanced quality. TSD
was central in the development of the Ford Production System (FPS) and its
world-wide roll-out to over 150 sites (FPS is Ford s adaptation of the Toyota
Production System (lean)). Also, TSD
currently serves a similar role with a multi-billion dollar fashion shoe and
apparel manufacturer in the development and Asia-wide roll-out of its proprietary,
lean-based operating system. And TSD is
currently serving as the guide-to-lean for several U.S. Air Force bases, as
part of the USAF s larger, organization-wide effort to implement lean systems,
to reduce waste, increase efficiency and drive down throughput times.
In addition to playing major roles implementing
lean at Ford, GM, DaimlerChrysler, Caterpillar, John Deere and other, TSD has
implemented lean in military aviation, aerospace, chemical, component
manufacturing, apparel, construction, and light assembly industries. Our
military applications have been focused on the maintenance of aircraft and the
process that support mission capability. TSD's current and past activities span the
globe, and recent lean initiatives are underway simultaneously in
II Description of
Services
TSD s services, as provided, are at times an
amalgam of and/or single focused element from all those services described in
SIN 874-1, 874-2 and 874-4.
Specifically:
SIN 874-1
Consulting Services
Strategic
Planning - TSD consultants possess over 150 collective
years of lean experience, and a significant portion of that time has been
devoted to exercising and refining their strategic planning skills. TSD is expert at developing strategic
business and action plans for reducing costs, increasing quality levels,
improving delivery times and integrating new entities. TSD has the vision and the years to see the
larger picture, and the skills to assemble individual plants and divisions into
a coherent and workable system. Performance Measures & Indicators -
TSD is expert in mapping clients manufacturing processes throughout the supply
chain. We uncover critical and often
hidden obstacles to value streams, use proprietary diagnostic tools to create
concise and understandable analyses of current situations, and present
practical solutions in detailed maps of the clients current and ideal future
states (Current & Future State Maps, Business Cases). Process/Productivity
Improvement, Cycle Time, High Performance Work - TSD provides comprehensive
long-term guidance for process and productivity improvement (lean)
implementation efforts. This ranges from
creating and executing focused pilot programs in single locations to
establishing full-scale multi-site efforts, including executive policy deployment
and alignment sessions, multilevel training programs, multiple and coordinated
shop floor events, and coaching/mentoring programs. Also, TSD is often called upon to quickly
isolate specific production-threatening process problems, and design and implement
short-term solutions. In all cases,
TSD s focus is to reduce waste, improve cycle time, even flow and generally
increase performance levels. Systems Alignment, Leadership Systems, Organizational Assessments - TSD has an
extensive repertoire of techniques and methods to align operational systems in
the midst of a lean implementation effort, as well as manage culture change and
shepherd and align an organization's culture in the midst of such a
change. TSD provides coaching and
mentoring programs, for training lean leaders and decision makers at all
levels, aligning their efforts within the larger corporate agenda, and managing
the change in their transition to lean-based systems. Also, TSD has proprietary tools for assessing
an organization s status and progress throughout the change process.
SIN 874-2
Facilitation Services
In TSD s role as change agent for
organizational/business/process improvement, TSD is expert in facilitating and
supporting agencies engaging in collaborative efforts, working groups, or
integrated product, process or self-directed teams. TSD is experienced in the use of, and
instruction in, problem solving techniques to improve processes and
productivity and resolve disputes and divergent views within organizational
systems. Integral to these services are
activities such as: setting agendas; focusing the decision-making process;
planning, convening, directing and debriefing meetings, working groups and
discussions; preparing draft and final reports for same; and providing logistical
meeting/conference support for the same.
It should be noted that while these services are identified under a
single SIN designation, from a practical perspective, TSD often provides such
services as an integral part of SIN 874-1
SIN 874-4
Training Services
While training activities are an integral part
of the services provided in SIN 874-1, TSD also provides off-the-shelf and
customized training packages to meet the specific agency needs as relates to
all subject matters related to management, organizational and business
improvement services, such as but not limited to process improvement, customer
service and team building, performance measurement, business process
reengineering, strategic planning, quality management, benchmarking, performance
problem-solving and change management.
For a more extensive list of day-long training modules, combined in any
configuration, see Attachment 5.
III Characteristics of TSD
Services
The
elements that distinguish TSD's capabilities and explain our consistent
success: (i)result-focused implementation experience
(ii)in-depth
lean expertise and its effective transfer
(iii)
flexibility tailoring lean to clients individual needs, and
(iv)
disciplined behaviors.
(i) Whether the project is
short or long-term, we never lose sight of the return, the economics of
implementation and committed clients frequently reap benefits from 7 to 20
times their consulting costs.
(ii) TSD operates with only
the highest qualified and dedicated lean manufacturing and change management
specialists, most with first-hand employment experience with Toyota Motor
Corporation, the founder of lean (each consultant averages 14 years of lean
experience). This means that our people
have lived lean systems personally and not merely vicariously through the
implementation efforts of others.
Moreover, our consultants are not merely shop floor practitioners, but
they also lecture and write on the principles of lean for organizations like
the Society of Manufacturing Engineers (SME).
In fact, TSD, through the collective efforts of its principals and
staff, has authored the recently released, 500 page reference book, Lean
Manufacturing: A Plant Floor Guide, published by SME (available at
amazon.com).
TSD is dedicated to timely and cost-efficient
transfer of lean knowledge, so the initial improvements in clients'
performance, flow and waste reduction continue long after the on-site
relationship with TSD has ended. This is
reflected in our improvement plans, prominently featuring "train-the-trainer"
courses and decreasing on-site presence over time. The watchword for each TSD-guided
implementation effort is sustainability.
(iii) Our clients are the primary focus of our work,
and each of our services bears the individualized stamp of their specific and
industry-related needs. Integration is a
feature of that flexibility. We work
with our clients' existing structure and improvement efforts, across all levels
of their organizations to build alignment and support for the improvement
effort. Moreover, each
organization begins in a different place, with differing objectives and degrees
of readiness. Success requires the
orchestration of improvement efforts on several levels, and it is TSD's ability
to operate on those levels that provides its clients with a discernible edge.
(iv) Disciplined behaviors are the foundation to
implementing lean, and sustaining the resulting improvements. TSD works with its clients to build and
continually strengthen that foundation.
Moreover, TSD programs install and maintain discipline behaviors
organization-wide. The importance of
consistency in following agreed-to standards applies to both management and
non-management personnel. And when the
inevitable breaks in discipline occur, TSD employs extensive coaching methods
and programs to bring behavior back online.
Internally,
TSD has operated the past 8 years with a quality control system that includes
regular work reports to supervisors and/or TSD principal(s), regular TSD-client
meetings and periodic reviews of results to assure conformance with specified
goals. TSD personnel assignments for
particular projects are made only after review and approval by the client. TSD is flexible in structuring billing cycles
to accommodate clients existing accounting systems and TSD s own accounting
controls include oversight by no fewer than two persons in the collection of
records and verification of billing accuracy.
Also, safety is an important feature of TSD services; TSD is fully
insured for the work it does and in the nearly 10 years of operation in client
factories around the world, TSD employees have not been involved in or the
cause of a single factory accident.
IV PRICING FORMATS
|
MOBIS SIN |
Skill Category |
Govt. Labor Rates (Loaded)* Clients Sites ($ per hour) |
|
874-1 |
Expert |
$ 289 |
|
874-2 |
Expert |
$ 289 |
*Includes the % industrial funding fee
MOBIS SIN
874-4
Course
Subjects: Process Improvement (Lean
Systems/Manufacturing), Problem Solving, Change Management, Benchmarking,
Quality Management, Strategic Planning, Performance Measurement, Customer
Service, Team Building (See Course Title Listing Below).
Skill
Category of Instructor: Expert
Course
Length: 1
Day
Minimum
Number Participants: 1 Participant
Maximum
Number of Participants: 25
Participants
Government
Rate (Loaded)
(Client
Site): $
1,805
Workbooks/Manuals: All books in
excess of 1 are charged at cost (approximately
$ 35 per course)
Course Titles: It should be noted that
the titles below are off-the-shelf products.
Customization to the individual client is available, and the cost is a
function of the time required to accomplish customization to client s
specification, at the rate of $ 289 per hour (government rate).
Course Description: Each course is designed to bring the participant
from neophyte to an intermediate level of subject-matter understanding. This is accomplished with a methodical
presentation of subject-matter elements, their definition, context and
application. Real-world examples of
elements/subjects are included in presentation methodology. In addition, each course includes
interactive activities, such as exercises and/or discussions of
participants /clients actual, on-site problems as they relate to subject
matter. This can only be accomplished
through the expert level status of TSD s instructors.
COURSE TITLES
Lean Manufacturing
Orientation
Introduction
to Lean Manufacturing
Roles and Responsibilities in the Implementation Process
Managing
Change in Lean Implementation
Integrating
Lean Tools
Metrics
Calibrate (This is a TSD proprietary organization assessment tool
incorporating sampling and measuring techniques and utilizes detailed and
in-depth assessments that are TSD-administered and scored. The product should be paired with current and
future state analyses (874-1), and culminates in a 68 page report with data
integrated into the 5-Phase Implementation Model).
The Tools of Lean
Standardized
Work & Takt Time
Visual Factory
Kaizen
Policy
Deployment
Problem Solving
& Systematic Thinking
Practical
Problem Solving
Quick
Changeover
Work Cell
Design
Mistake
Proofing
PDCA
Management
Kanban (Pull Systems)
Effective Work Group Relations
Work site communications
Group Facilitation
Group Dynamics
Team Leader Training
Conflict Resolution
Job Relations
Systematic Management
Leadership
Alignment & Change Management
Course
Title: Role-Playing Manufacturing Simulation
Demonstrating the Transition from Mass Production to Lean.
Skill
Category of Instructor: Expert
Course
Length: 1
Calendar Day 2 Instructors
Minimum
Number Participants: 14 Participants
Maximum
Number of Participants: 21
Participants
Government
Rate (Loaded)
(Client
Site): $
6,475
Workbooks/Manuals: Included
Course
Description:
This simulation is a powerful
off-the-shelf, hands-on approach to learning about the change from mass
production to lean manufacturing. It
familiarizes participants with lean concepts, their implementation and the
benefits of lean thinking and manufacturing.
This four round simulation educates through first-hand experience. Participants experience manufacturing
methods in progressive modes, as job assignments are introduced, metrics are defined,
data is collected and analyzed, improvements are made, and changes are discussed
after the manufacturing experience of each round.
Course
Title: Lean Boot Camp
Skill
Category of Instructor: Expert
Course
Length: 5
Calendar Days (1 Instructor for 5 days, 2nd Instructor
for Simulation on Days 1 & 2)
Minimum
Number Participants: 14 Participants
Maximum
Number of Participants: 21
Participants
Government
Rate (Loaded)
(Client
Site): $
27,750
Workbooks/Manuals: Included
Course
Description:
Lean
Boot Camp
is a week-long, partially customized training program dedicated to a
fundamental understanding of lean principles and their application in the
client s existing manufacturing environment.
It consists of two days of integrated lean simulation (see course
description above) and classroom training, followed by three days of hands-on
activities on the shop floor, making improvements and measuring their effects
(integrated with some classroom training selection of subject matter is
customized to each client).