OptimaFlow

Modular OpEx Intelligence

Professional
Active
AI Status

All systems operational

Operational Excellence Frameworks

Build manufacturing excellence through structured progression

OpEx Journey - Where to Start

Progressive framework implementation from foundation to mastery

Level 1

5S

Structure

Execution

Foundation for workplace organization and visual management

Overall Progress65%
1 completed
2 in progress
1 pending
Level 2

Kaizen

Overview & Insight

Scaling

Continuous improvement culture with visual management and KPIs

Overall Progress71%
1 completed
2 in progress
1 pending
Level 3

Lean

Stability

Piloting

Elimination of waste and creation of flow in processes

Overall Progress60%
1 completed
2 in progress
1 pending
Level 4

DMAIC Six Sigma

Capability

Planning

DMAIC (Define, Measure, Analyze, Improve, Control) - Data-driven approach to reduce variation and improve quality

Overall Progress35%
0 completed
2 in progress
2 pending
Level 5

DFSS

Robustness

Not Started

Design for Six Sigma - building quality into products and processes

Overall Progress0%
0 completed
0 in progress
4 pending
Level 4

TPM

Total Productive Maintenance

Scaling

Maximizing equipment effectiveness through proactive and preventive maintenance

Overall Progress63%
1 completed
2 in progress
1 pending
Level 4

Poka-Yoke

Error Proofing

Piloting

Designing processes and equipment to prevent errors before they occur

Overall Progress58%
1 completed
2 in progress
1 pending
Level 4

SMED

Quick Changeover

Execution

Rapid changeover techniques to minimize equipment setup time

Overall Progress78%
2 completed
2 in progress
0 pending

Key Principles

  • Work environment optimization
  • Procedures & Instructions standardization
  • Abnormalities made visible
  • Sort, Set in Order, Shine, Standardize, Sustain

Expected Benefits

  • Improved workplace safety and cleanliness
  • Reduced time searching for tools and materials
  • Enhanced visual management
  • Foundation for continuous improvement

Performance Metrics

Workplace Organization Score
87%
Target: 95%
5.2%
Visual Management Compliance
82%
Target: 90%
3.8%
Standard Work Adherence
78%
Target: 85%
4.1%

Implementation Activities

Complete workplace audits

Due: 2025-12-15

100%

Implement visual controls

Due: 2026-01-30

75%

Train all operators on 5S standards

Due: 2026-02-15

60%

Establish daily inspection routines

Due: 2026-03-01

25%

AI-Powered Improvement Opportunities

Machine learning and reinforcement learning recommendations for 5S

Digital Visual Management System

HIGH Impact
MEDIUM Effort
Priority: 5/5

Implement AI-powered image recognition for 5S audits. Use computer vision to automatically detect violations and track compliance over time.

Estimated Annual Savings
$45,000
Implementation: 3-4 months
RL-Optimized Action Plan

Deploy visual AI system in Line 3 first (highest traffic area), then scale. Start with shadow mode for 2 weeks to build confidence.

AI Confidence92%

Mobile 5S Inspection App

MEDIUM Impact
LOW Effort
Priority: 4/5

Enable operators to submit real-time 5S observations via mobile app with photo/video evidence. Gamify participation with leaderboards.

Estimated Annual Savings
$28,000
Implementation: 1-2 months
RL-Optimized Action Plan

Pilot with shift A team first. Offer incentive for highest participation rate. Use feedback to refine before full rollout.

AI Confidence88%

Shadow Board Optimization

MEDIUM Impact
LOW Effort
Priority: 3/5

Redesign tool shadow boards based on motion study data. Optimize tool placement to reduce search time by 40%.

Estimated Annual Savings
$18,000
Implementation: 2-3 weeks
RL-Optimized Action Plan

Start with maintenance area (highest tool usage). Track time-to-tool metric before and after to validate savings.

AI Confidence85%
Total Potential Annual Savings
$91,000
Opportunities Identified
3

AI-Powered 5S Visual Audit

Upload a photo or video of your workspace for instant AI analysis of 5S compliance