We can help you with production efficiency software and services

Our OEE (Overall Equipment Effectiveness) software module focusses on maximising your production output whilst maintaining product quality.  It’s the ideal KPI to help you benchmark plant and process efficiency and identify areas for improvement. We teach you how to use the real time data visually to drive sustainable improvement. 

Get a real-time snapshot view on your Andon screen of what’s currently happening on your shop-floor. Our Andon Board Manager gives you a flexible and user-configurable display showing live production status and a whole host of extra features.

Transmit requests for support (i.e. maintenance required, machine breakdown, no materials etc.) from the shop-floor via email, lamp tower etc, with a closed-loop escalation process to ensure issues are dealt with effectively. Historical data analysis will identify and correct weak spots, repetitive problems and slow response times.

Allows you to monitor and analyse labour movement, measure labour performance, count lost hours and calculate cost per part produced. This software will help you to define and match skills to production processes, ensuring that people with the right skills are allocated to each machine/job at the right time.

Our software provides a simple mechanism through which key production data can be gathered and stored against the job or part to which it relates.  By embedding links to part/job specific documentation (e.g. work instructions) we can help you to remove unnecessary paperwork from the shop-floor.  

This software allows works order requests to be placed and corresponding works orders to be raised, tracked and analysed.  Where equipment is covered by a maintenance contract, service contracts can be raised and tracked with the maintenance calendar providing a clear view of planned and outstanding maintenance activities.

Gemba’s software provides a comprehensive set of reports as standard.  However where something different is required our Custom Reporting module allows data to be exported, manipulated and presented in user-definable Excel reports. Ideal for change management situations where users need a stepping stone between existing methods and a new approach.

If you want to improve it you have to measure it! Gemba’s software offers a real-time solution to capturing accurate and unambiguous data about your production processes. It will help you to analyse this data quickly and easily and get to the heart of your production issues and bottlenecks.

This software gathers and stores analogue data relating to processes (e.g. Temperatures, pressures, speeds, energy consumption, etc) and displays it as a user-definable set of trends. This is an excellent tool for cause and effect analysis, enabling associations to be made between process exceptions (e.g. poor quality) and process variables (e.g. over-temperature).

Our Computerised Maintenance Management System module integrates seamlessly with your data capture system to provide live and historical maintenance records. Its simple design encourages use and interaction by operators and management, its richness of data enables good maintenance decisions to be made. 

Need a set of tools to get an overview of the actual workload on the shop-floor? Our Job Sequencing Manager gives planners control of exact intelligence on predicted job start and end times, based on actual performance rather than theoretical standards.

Our Short Interval Control module will provide you with a mechanism to visually illustrate, collect and analyse data at regular short intervals, and to implement and verify the effectiveness of corrective actions.

Our Inventory Tracking module is used to track production materials (raw materials, WIP, finished goods, assemblies, sub-assemblies, bought-in components, etc.) through an area or a process. The tracking information gathered is used to monitor part location and stock levels in real-time and to reconcile stock levels and determine product velocity after the event.

Having an organised and safe workplace is the basis of any Lean/Agile improvement programme. This training will help your team to identify and quantify efficiency losses and understand how to sustain improvements made through behavioural practices, visual management, documentation and audits that ensure a safe and efficient workplace.  

Learn about the difference between the symptoms and causes of problems affecting performance. Capture the influencing factors, get to root cause, generate corrective action plans and practice their use with your team.

As specialists in lean manufacturing, we will listen to your needs and help to educate your teams in using a variety of tools that will address your key production issues.  We can train both in the workplace and in our specifically designed Lean Manufacturing War Room.

Our Practitioners will work with you to define and generate your ideal state vision and strategy and then support your teams in identifying and monitoring improvement activities that are aligned with your business objectives.

Short Interval Control training will equip your teams with a powerful rapid improvement tool that helps focus their value adding activities. SIC reviews the recent past, typically every hour, and makes improvements to prevent repeating the losses. Trending this improvement activity can ensure there are no surprises at the end of a shift.

Gemba provides all the tools and training necessary to install a CI culture into your business and develop, roll out and sustain processes and activities that generate real benefits to your customers, employees and bottom line.

TPM aims to remove the unpredictability of machine performance caused by failures of equipment. This process involves operators in the maintenance of the machine assets, giving them access to our CMMS software module and the training to carry-out simple routine tasks. This releases the technically trained tradesmen to concentrate on design improvements, root cause analysis of failures, and continuous improvement activities.

This SMED training will improve the flexibility and responsiveness of your company and will reduce waste by shortening changeover times in your workplace. This training is all about shorter lead times, which is a key ingredient for adaptability and customer focus.

Explore some of our best projects

Let's go!

Stay in touch

Sign up to our mailing list and we’ll keep you up to date.

Copyright © 2016 Gemba Solutions - All rights reserved
Privacy & Cookies

Privacy & Cookies

This site uses cookies. By continuing to use this website, you agree to their use. To find out more, please read our Privacy policy.